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. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on which they operate.
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. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 This section describes safe vehicle operation and identifies warning decals and their locations. Features . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.
INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
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.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Operator Safety SAFETY Follow the recommended maintenance program outlined beginning on page 70 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.
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.
Operator Safety 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 conditions you may encounter.
SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death.
Operator Safety 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.
SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S 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.
Operator Safety SAFETY Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward.
Operator Safety SAFETY Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches.
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 little snow will result in excessive wear and damage to the slide rail, track and/or engine.
Operator Safety SAFETY Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed in MPH Actual Thermometer Reading (°F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 -20 -34 -41 -45 -48 -51 -53 -55 -57 -58 -60 -61 -62 -25 -30 -40 -46 -47 -53 -51 -58 -55 -61 -58 -64 -60 -67 -62 -69 -64 -71 -65 -72 -67 -74 -68 -75 -69 -76 5 min.
Safety Decals and Locations SAFETY Warning decals have been placed on the snowmobile for your protection. 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.
SAFETY Safety Decals and Locations Track Warning + Warming Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” Warning Warming This vehicle is designed for operator only.
Safety Decals and Locations + SAFETY + Reverse Warning Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: S S S S Look behind before and while backing. Avoid sharp turns. Shift to or from reverse only when stopped. Apply throttle slowly. NOTE: For more information, see Owner’s Manual. If electric reverse: S Machine stopped and engine at idle, push yellow button on LH control to reverse.
SAFETY Safety Decals and Locations Operation Warning S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before + operation. If the manual is miss+ ing, contact a Polaris dealer for a replacement. S 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.
1. 2. 3. 4. 5. 6. 7. 8. Hood Headlight Windshield Handlebar Side Shield Seat Storage Compartment Taillights FEATURES 9. 10. 11. 12. 13. 14. 15. 3 4 Rear Bumper Snow Flap Suspension Track Nosepan Front Bumper Ski 6 5 8 7 9 2 7 1 10 12 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 14 13 Fuel Filler Cap Rider Selectt Ignition Switch Handlebar hook Brake Lever Mountain Bar MFD (Multi-Function Display) Engine Stop Switch Choke 6 5 4 10. 11. 12. 13. 14. 15. 16. 17. 18.
FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. Choosing the Best RIDER SELECTt Position Position 26 Riding Style 1 2 3 Relaxed Trail Riding 4 5 General Trail Riding, Boondocking, Deep Snow Riding 6 7 Snowcross & Steep Hill Climbing Only Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding.
FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2. Press the release button and move the handlebar forward or rearward to the desired position. WARNING Do not lubricate the RIDER SELECT mechanism.
FEATURES Fuel Valve The fuel valve is located under the hood. Turn the fuel valve off whenever the snowmobile is stored or parked. 1. Turn the valve clockwise to turn off the fuel supply. 2. Turn the valve counter-clockwise to turn on the fuel supply. 1 Seat Storage Compartment Lift the seat lever (+) and lift the seat to access the under-seat storage area. + Radiator Compartment Access Panel The access panel (+) is provided for cleaning debris from the radiator.
FEATURES Detonation Elimination Technology (D.E.T.) The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely. A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing. This can result in decreased engine RPM and performance. The engine is designed to provide maximum power when premium (91 octane) fuel is used.
FEATURES Instrumentation MFD Component Identification Item 2 1 1 Analog Gauge 2 Digital Gauge 3 DET Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 3 5 4 6 7 8 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 1 2 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers per hour RPM - Engine crankshaft revolutions per minute 4 Air Temp (if equi
FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch (1) to set the 1 MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of 2 measurement. While viewing a 3 screen that displays measurements (MPH, KPH or temperatures), press and hold the MODE switch until the unit of measurement changes (about 10 seconds).
FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting is selected) regardless of the display program being viewed. Performance Program The Performance Program automatically displays either speed or tachometer, whichever is opposite the analog display. See page 31.
Instrumentation FEATURES MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the hour once every 0.2 seconds. 3. Press the MODE button to save the hour and flash the minutes. 4. Set the minutes in the same manner. 5. When finished, press the MODE button to save the new setting.
FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement. When “ALt” displays, the program is in the metric mode. 1. Enter the Engine Program and select the altimeter display. 2. Press and hold the SET button for five seconds. 3.
Instrumentation FEATURES MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed.
FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. “SErVCE” will flash in the odometer area and “ENG” will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset. To reset the reminder at the existing interval: 1.
Instrumentation FEATURES MFD Battery Replacement If the clock function of the MFD isn’t 1 working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery 2 compartment (1). It has a red wire and a brown wire with a white stripe. It’s located about three inches down the main harness from the point where the harness connects to the MFD. 3.
FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or protective rubber boot. Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source. CAUTION To prevent damage to the lens, do not use alcohol for cleaning.
THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempting to adjust preload. Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension. Decreasing the spring preload too much may allow the upper spring retainer to fall off.
THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail.
THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the suspension.
THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.
THE PERFECT FIT Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Locate the adjustment screw (L) near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride.
THE PERFECT FIT Rear Suspension Adjustments Rear Shocks ARVIN Rapid Adjust Shock The ARVIN Rapid Adjust shock is available as an option on some models. Turn the Rapid Adjust knob (L) on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly, then test ride.
THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 26. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). NOTE: 1 2 If necessary, remove the mountain bar (3). 2.
Accessories THE PERFECT FIT Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: S Non-compliance with government/industry requirements S Voiding of warranty S Injury to self or others This applies, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.
THE PERFECT FIT Traction Products (SwitchBack only) Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. See your dealer about installing studs and/or carbides.
THE PERFECT FIT Traction Products (SwitchBack only) n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 103. If your machine has carbide skags, it may be necessary to add track studs to maintain proper vehicle control.
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 referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items.
PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. 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.
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 snowmobile.
PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. 1/2″ (1.3 cm) Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 90. Lever Feel If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition.
PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock Use the park brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 3 2 2. Park Brake Lever Lock 4 1 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.
PRE-RIDE INSPECTIONS Before Starting the Engine n Track WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. Use of traction products such as studs increases the possibility of track damage and/or failure.
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 Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n Tether Switch If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately. n Lighting Check the headlight (high and low beam), taillight, and brake light.
OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 51. Starting a Cold Engine Do not depress the throttle until the engine starts. 1. Turn the fuel valve on. See page 28. 2. Turn the key to the ON position. 3. Pull the engine stop switch up to the RUN position. 4.
OPERATION Starting the Engine Starting a Warm Engine 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. Grasp the recoil rope handle and pull slowly until the recoil engages; then pull abruptly. NOTE: If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4” open), and pull the rope with your right hand. When the engine starts, immediately release the throttle.
Engine Break-In OPERATION Oil Injection System Always fill the oil tank when refueling. See page 63. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn’t go down, contact your dealer immediately. Oil Recommendations This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems.
OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
Fuel OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill the tank neck. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended. Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank. Do not allow the snowmobile to run out of fuel.
Oil n Low Oil Indicator Light OPERATION The low oil indicator light will alert the operator if the oil level is low. Visually check the oil level in the bottle. Add oil before further operation of the snowmobile. See page 59 for oil recommendations. n Low Oil Level Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage. This is especially important when the machine is operated in mountainous terrain.
OPERATION n Engine Stop Switch Push down on the engine stop switch (L) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch L 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.
Throttle Lever OPERATION WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. Turn the ignition switch to OFF. 2. Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate. 3.
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 64 for more information about the engine stop switch and throttle safety switch.
OPERATION Emergency Starting If the recoil starter system fails, an emergency start strap is provided in the tool kit. 1. Open the hood. 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. Starting at one of the tower struts, wind the strap counterclockwise around the clutch as shown. WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure.
OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. 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. S Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle. S Look behind the vehicle before and while backing.
Daily Storage OPERATION At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the machine. Towing 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.
MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance 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).
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 P Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page P Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Lubrication Front Suspension The front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your Polaris dealer.
Lubrication Driveshaft Bearing MAINTENANCE + Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubricate the choke slide and cables lightly with oil or grease.
MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Polaris recommends the use of Polaris Synthetic Chaincase Lube.
Lubrication MAINTENANCE Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely 3. Install a new sealing washer on the drain plug. NOTE: 4. 5. 6. 7. 4 The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm). Remove the fill plug. Add 11 oz. (325 ml) of the recommended oil.
MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION Using non-recommended spark plugs can result in serious engine damage.
General Maintenance 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. 1. Normal The normal insulator tip is gray, tan or light brown.
MAINTENANCE General Maintenance + Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile.
General Maintenance MAINTENANCE Oil Filter/Oil Lines Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch. Have your dealer perform the filter change and bleeding operation. NOTE: The direction of the arrows indicates the direction of flow through the filter.
MAINTENANCE General 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. CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly.
General Maintenance MAINTENANCE Carburetor Water/Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination. WARNING When draining the traps, fuel spillage will occur.
MAINTENANCE General Maintenance Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 108 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system.
General Maintenance MAINTENANCE Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service. Add coolant if the level is low.
MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result.
General Maintenance MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (1). 3. Finger tighten the adjuster bolt (2) until it can no longer be adjusted by hand, then back off 1/4 turn. 4.
MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 53. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″). A kit is available for replacing brake pads. See your dealer. WARNING Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety.
General Maintenance MAINTENANCE Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury. WARNING Keep the master cylinder cover free of dirt and debris.
MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever. During the bleeding procedure, keep the brake handle as level as possible.
General Maintenance MAINTENANCE Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum covering from the headlight assembly. 2 2. Lift the rubber boot to expose the bulb. 3 3. Push down on the spring (1) to release it from the housing. 1 4.
MAINTENANCE General Maintenance Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer.
General Maintenance n Drive Belt Condition MAINTENANCE Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 113. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile.
MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the belt removal procedures. 2. Rotate the L-wrench counter-clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves. 3.
General Maintenance 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 (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4” (3.2 cm). MAINTENANCE A B Drive Belt Adjustment TEAM Clutch 1. Loosen the 7/16” jam nut on the belt width adjuster. 2. Using a 1/8” Allen wrench, adjust the threaded set screw as needed.
MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. 1. Emergency Start Strap 2. L-Wrench 3. Spark Plug Wrench/Screwdriver 4. Scissor Stop Wrench 5. Combination Wrench 6. Open End Wrench 1 2 3 4 5 6 Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer.
Track Maintenance MAINTENANCE Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 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 damage. 3. Carefully examine the track along the entire length of each rod (L).
MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber. 1. Turn the machine off. 2.
MAINTENANCE Track Maintenance Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A). 7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on the other side of the track. NOTE: Rail Slide B A Weight C D Track Check more frequently when the machine is new. 9. Start the machine and slowly rotate the track at least five revolutions.
MAINTENANCE Track Maintenance n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a + stop (do not apply brakes). 3.
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
Steering System n Ski Skags MAINTENANCE 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.
MAINTENANCE Steering System n Rail Slide Measure slide thickness at several points along the rail. Have your dealer replace the slide when it’s worn down to the top of the wear groove (+). Do not operate the snowmobile if slide thickness measures less than 7/16″ (1.1 cm). 7/16″ (1.1 cm) + Suspension Maintenance n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time.
Suspension Maintenance MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 108 for the part numbers of Polaris products. 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.
MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer.
Extended Storage MAINTENANCE Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1.
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.) 2874438 VES II Synthetic 2-Cycle Engine Oil (qt.
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine Drive clutch binding operating RPM during Driven clutch acceleration or load varia- malfunction tions S Harsh drive clutch engagement Drive belt worn or too narrow S Replace the drive belt. Excessive belt/sheave clearance S SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive system Broken drive clutch components S SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft S SEE YOUR DEALER. Drive belt surface flat spots Drive chain loose S Inspect and replace as needed. Drive chain worn, sprocket teeth broken Worn drive belt S SEE YOUR DEALER. Excessive belt/sheave clearance Loose torque stop S SEE YOUR DEALER. Sticky clutch S SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition S Install new spark plug(s). If engine still fails to start, check for spark. If there’s no spark, SEE YOUR DEALER. No fuel to engine S S S S Poor engine compression S Mixture is too lean. This indicates a major engine problem that must be repaired before the engine is run. SEE YOUR DEALER.
TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Verify sag dimension (see page 42). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. - Increase shock compression damping (see page 44). Rear suspension rides too stiff - Check for binding suspension components and grease all pivot points. - Verify sag dimension (see page 42).
TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM S Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up S Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM S Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
Limited Warranty WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty. The warranty begins on the date of purchase. This warranty is transferrable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES 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.
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 PreDelivery 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.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. 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.
MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 121
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . . 47 Adjustable Headlights . . . . . . . . . . . . 28 Avalanches . . . . . . . . . . . . . . . . . . . . 14 B Bearings . . . . . . . . . . . . . . . . . . . . . 106 Before Starting the Engine . . . . . . 51-55 Belt Troubleshooting . . . . . . . . . . . 113 Bleeding the Cooling System . . . . . . 86 Bleeding the Hydraulic Brake System 90 Brake Components . . . . . . . . . . . . . . 88 Brake Fluid . . . . . . . . . . . . . . . . . . . .
INDEX H Halogen Bulbs . . . . . . . . . . . . . . . . . Handlebar Adjustments . . . . . . . . . . . Handlebar Angle . . . . . . . . . . . . . . . . Handlebar Position . . . . . . . . . . . . . . Headlights . . . . . . . . . . . . . . . . . . . . . High Temperature Indicator . . . . . . . Hydraulic Brake Inspection . . . . . . . . P 91 46 46 46 28 85 88 Passenger . . . . . . . . . . . . . . . . . . . . . 22 PERC . . . . . . . . . . . . . . . . . . . . . . . . 68 POLARIS PRODUCTS . . . . . . . . .
INDEX S V Starting, Emergency . . . . . . . . . . . . . 67 Steering Adjustment . . . . . . . . . . . . 101 Steering Inspection . . . . . . . . . . . . . 101 Steering System . . . . . . . . . 52, 101-104 Stopping . . . . . . . . . . . . . . . . . . . . . . 66 Storage . . . . . . . . . . . . . . . . 69, 105-107 Storage Compartment . . . . . . . . . . . . 28 Studs . . . . . . . . . . . . . . . . . . . . . . . . . 48 Survival Preparation . . . . . . . . . . . . . 11 Suspension . . . . . . . . . . . . . . . .
