Pantone 425C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No.
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.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recreational products.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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 the snowmobile is 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.
SAFETY Operator Safety Follow the recommended maintenance program beginning on page 90 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time. Snowmobiles are capable of traveling at high speeds.
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 Riding Apparel Be prepared, be warm and be comfortable 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.
SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone.
SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. Machines designed for two riders should never be operated with more than two people on board.
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.
Operator Safety 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.
SAFETY Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
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.
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.
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 “No Passenger” Warning Snowmobiles designed for a single rider only have the NO PASSENGER warning decal on the lower left side of the console: WARNING This vehicle is designed for operator only. NO PASSENGER “One Passenger” Warning Snowmobiles designed for an operator and one passenger have the ONE PASSENGER warning decal below the steering post: WARNING This vehicle is designed for operator and ONE passenger only.
Safety Decals and Locations Reverse Warning SAFETY Reverse Warning The reverse warning decal is located on the console, either beside the steering post or below the windshield: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look behind before and while backReverse Warning ing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly.
SAFETY Safety Decals and Locations Operation Warning • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact 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.
FEATURES 8 11 10 12 13 7 6 9 5 14 4 15 3 16 17 1 18 600 IQ Touring Shown 2 Not all models are equipped with all features shown. 1. Nosepan 2. Skis 3. Front Bumper (do not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Handlebar 8. Mirrors (if equipped) 9. Operator Seat 10. Passenger Seat (Touring) 11. Backrest (Touring) 12. Passenger Grab Handle (Touring) 13. Grab Handle Heater Switch (Touring) 14. Taillights 15. Rear Bumper 16. Snow Flap 17. Suspension 18.
FEATURES 5 4 6 3 7 2 1 8 9 Not all models are equipped with all features shown. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions. WARNING If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability.
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 Cargo Area The maximum weight capacity for the cargo area (except Touring) is 15 lbs. (7 kg). Install only accessories specifically approved for this model by Polaris. Always secure cargo before operating. Do not exceed the cargo area weight limit. Cargo Bag (Touring) + Cargo Bag The cargo bag is secured to the rear of the tunnel with straps. The cargo bag and the passenger seat are removable to provide open storage for transporting larger items.
FEATURES Backrest (Touring) Raise/Lower The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest forward for operator use or rearward for passenger use. 3. Always tighten the knobs securely after adjusting. Operator/Passenger Passenger Grab Handle On some Touring models the position of the passenger grab handles can be adjusted for rider preference. 1.
FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation. You may notice decreased engine RPM and performance when DET is activated, but in most cases DET activation is temporary, and the timing will return to normal automatically. In extreme conditions the DET system retards timing and holds it in a retarded state.
FEATURES Instrumentation MFD Component Identification Item 1 Analog (if equipped) 2 1 2 Digital Gauge 3 CHECK ENGINE Indicator (carb models) 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 3 4 5 6 7 8 8 High Beam Indicator 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
FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch (+) has a MODE button (top) and a SET button (bottom). + Standard vs. Metric The MFD will display either standard or metric units of measurement. While viewing a 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 35.
Instrumentation FEATURES MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. Press and hold the SET button for two seconds. If the snowmobile is equipped with an electronic fuel gauge, Trip F automatically displays when the fuel level is low.
FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the hour once every 0.2 seconds. 3. Press the MODE button to save the hour and flash the minutes. 4. Set the minutes in the same manner. 5. When finished, press the MODE button to save the new setting.
Instrumentation FEATURES MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air temperature will display as additional screens in the engine program. Press the SET button to display the ambient air temperature and altitude screens.
FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 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.
Instrumentation FEATURES MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval 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 (models with clocks) If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment. 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 MFD Battery Replacement (models with clocks) 6. Install a new battery with fingers only. 7. Seal the end of the battery compartment using high strength doublesided tape between the two compartment halves or high strength single-sided tape around the outside of the compartment. 8. Make sure the taped seam of the compartment faces the downward side of the wire harness. 9.
THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE 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. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it. Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension.
THE PERFECT FIT Front Suspension Adjustments Shock Valving Some shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. Please see your Polaris dealer. WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment.
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 snowcross racing would provide a very stiff ride on the trail.
THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride. • In deep snow, a new rail slide will offer improved performance over worn rail slide. It can also improve top speed.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension. X NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. Tighten the straps to increase ski pressure. Loosen the straps to reduce ski pressure. Upper Nuts 1. Remove the nuts and flat washers from the upper limiter straps. 2.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear Shock Compression Damping (Premium Shocks) Turn the adjustment knob 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. • Turn the knob clockwise (A) for a stiffer ride. • Turn the knob counterclockwise (B) for a softer ride.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other. There are two types of rear suspension coupling.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position. To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride. Please take the time to read and understand all the possible adjustments available with this suspension.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown in the illustration. Record the measurement. 2. Have the rider sit on the snowmobile and bounce up and down on the seat a few times to set in the suspension.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments M-10 Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the most effect on the rear suspension performance. To adjust the FRA: 1. Refer to the initial set-up reference chart (page 63) to determine the desired FRA position. 2. To adjust, loosen the hex bolts (1) attaching the rear lower shock cross shaft to the rail beam. 3.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments M-10 Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag. See your Polaris dealer for assistance.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount. 4 1. Determine if the rider prefers comfort or con3 trol. Lean toward the #4 2 setting for comfort and 1 toward the #3 setting for aggressive riding. 2.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure NOTE: By design, the BIASED COUPLE design of the M-10 suspension displaces the rear arm as the front arm is compressed. This means that when you raise the front limiter strap, at some point you will collapse the rear suspension arm, which will affect SAG height and reduce rear suspension travel. Initial M-10 Suspension Set-up Chart These charts are a guideline to be used for initial suspension set-ups.
THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 29. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. Handlebar Cover NOTE: If equipped, remove the mountain bar. 2. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).
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: • Non-compliance with government/industry requirements • Voiding of warranty • Injury to self or others This applies, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.
THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track 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. CAUTION Always install wear strips before installing studs.
Traction Products THE PERFECT FIT nCarbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 125. 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 Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.
PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 110 or see your dealer for service. 1/2I (1.
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indicator 2 3 4 1 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 Steering System WARNING Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
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 Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 69. 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.
OPERATION Starting the Engine CAUTION Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. If equipped with electric start, turn the key to START to crank the engine. Release the key to the ON position when the engine starts. 4.
OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in. CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts.
OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 81. 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. Use a stable rear support. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. • • • • • Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank neck. Do not smoke or allow open flames or sparks in or near the area where 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 lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). CAUTION Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended. Prolonged exposure to petroleum based products may damage paint.
OPERATION n Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 77 for oil recommendations. 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 (+) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. + n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.
OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. Turn the ignition switch to OFF. 2. Visually inspect the throttle cable and carburetor/throttle body to determine what caused the safety switch to activate. 3.
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 82 for more information about the engine stop switch and throttle safety switch.
Electronic Reverse (PERCt) OPERATION 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. • 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.
OPERATION Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the transmission is in reverse. 4. Apply the throttle slowly to make sure the transmission is in reverse.
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the machine. Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.
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 control information (ECI) label and a factory-installed emissions information hangtag. These items are required by U.S. Environmental Protection Agency regulations.
Emission Control Information MAINTENANCE Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 144, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed, including the emission-related maintenance outlined in these sections of the manual.
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 146. 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 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 Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 90 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your Polaris dealer.
MAINTENANCE Lubrication Rear Suspension M-10 128 Rear Suspension + + + + M-10 136 Rear Suspension + + + + 95
MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. + Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.
MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 90. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. 3 Polaris recommends the use of Polaris Synthetic Chaincase Lube.
MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. 4 NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches. 5. 6. 7. 8. 98 Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
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. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine. Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION Using non-recommended spark plugs can result in serious engine damage.
MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits.
MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm). 5. Reinstall the spark plug cap. Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank.
MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. + 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.
MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your Polaris dealer. When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use.
MAINTENANCE Cooling System Coolant High Temperature Indicator Light WARNING Steam and hot liquids will cause serious burns to your skin. Never remove the pressure cap when the engine is warm or hot. The high temperature indicator light will illuminate when engine 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.
MAINTENANCE Cooling System Bleeding the Cooling System WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result.
MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. 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. 1. Open the hood and inspect the muffler and pipes for cracks or damage. 2. Check for weak or missing retaining springs or damper/support grommets. 3.
Drive Chain Tension MAINTENANCE 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. Tighten the jam nut while holding the adjuster bolt.
MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 70. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). A kit is available for replacing brake pads. See your dealer. WARNING Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety.
MAINTENANCE Brakes Brake Fluid 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. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 130 for the part numbers of Polaris products. WARNING After opening a bottle of brake fluid, always discard any unused portion.
MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever. During the bleeding procedure, keep the brake handle as level as possible.
Lights MAINTENANCE 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 alcoholmoistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the headlight assembly. 2. Lift the rubber boot to expose the bulb. 2 3. Push down on the spring (1) 3 to release it from the housing. 4.
MAINTENANCE Lights Taillight/Brakelight Replacement IQ LX 1. Open the rear storage compartment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. 5. Install a new bulb. Reinstall the socket assembly. 6. Secure the storage compartment door. IQ/SwitchBack 1. Remove the screws securing the taillight lens. Remove the lens. 2.
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.
MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 136. Always carry a spare drive belt for emergency use. Store the spare belt on top of the electrical box, which is mounted to the clutch cover.
Clutch System MAINTENANCE n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. 1 2 Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm). Drive Belt Adjustment 1. Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 116). Turn the wrench clockwise slightly to remove pressure from the sheaves. 2. Loosen the 7/16I jam nut. 3.
MAINTENANCE Clutch System Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt. 1. Stop the engine after operating in a forward motion. 2. Turn the ignition key off. + Wait for the engine to come to a complete stop. 3.
Clutch System 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 counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves. 3.
MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Track Maintenance Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1.
MAINTENANCE Track Maintenance Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication. The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication.
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. TRACK TENSION DATA CHART Suspension Slack Measurement IQ 121 Switchback 136 M-10 128 M-10 136 7/8"-1 1/8" (2.2-2.
MAINTENANCE Track Maintenance Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 120. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. Adjusting Screw Lock Nut Slack Measurement Track S Shaft Bolt 16I(40 cm) 10 lbs. (4.54 kg) 7. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track. 8.
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.
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.
MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove (+). Do not operate the snowmobile if slide thickness measures less than 7/16I (1.1 cm). 7/16I (1.1 cm) + Suspension Maintenance n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time.
Extended Storage MAINTENANCE 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 130 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. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly. 2. Tie the snowmobile to the transporting unit securely using suitable straps. 3. Remove the ignition key to prevent loss.
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.
Engine Troubleshooting TROUBLESHOOTING Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch malfunction • SEE YOUR DEALER. Harsh drive clutch engagement Drive belt worn or too narrow • Replace the drive belt. Excessive belt/ sheave clearance • SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or replace). Drive chain worn, sprocket teeth broken • SEE YOUR DEALER. Worn drive belt • Inspect and replace as needed.
Engine Troubleshooting TROUBLESHOOTING Problem Probable Cause Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Make sure the fuel tank contains fuel. • Ice may be in the fuel line, filter or pump. Add isopropyl alcohol to the fuel system. Poor engine compression • Mixture is too lean.
TROUBLESHOOTING IQ/Switchback Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust torsion spring preload to achieve proper static sag (see page 50). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for binding suspension shafts and grease all pivot points. • Adjust torsion spring preload to achieve proper static sag (see page 50).
TROUBLESHOOTING M-10 Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Increase FRA position (see page 60). • Install appropriate optional center retainer on rear track shock (see page 61). • Increase front track shock coil spring preload. • Revalve rear track shock (see your dealer). • Check track tension (see page 120). Rides too stiff in rear • Decrease FRA position (see page 60). • Install appropriate optional center retainer on rear track shock (see page 61).
TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM • Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
Service and Warranty Information WARRANTY 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.
WARRANTY Service and Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2.
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 transferable 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.
Conditions and Exclusions WARRANTY 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.
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.
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 the new engine, including all parts of its emissioncontrol system, is designed, built and equipped so it conforms to current U.S. Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser.
WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use.
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 147
MAINTENANCE LOG DATE 148 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . . 65 Adjustable Headlights. . . . . . . . . . . . 31 Adjustable Steering System . . . . 29-30 Air Pollution . . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 Drive Belt. . . . . . . . . . . . . 19, 114-117 Adjustment . . . . . . . . . . . . . . . 115 Condition . . . . . . . . . . . . . . . . 114 Deflection . . . . . . . . . . . . . . . . 115 Installation . . . . . . . . . . . . . . . 117 Removal . .
INDEX I R Ice and Snow Build-up . . . . . . . . . . 16 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 45 IFS Adjustment Options . . . . . . . . . 45 IFS Components . . . . . . . . . . . . . . . 45 Inadequate Snow Conditions . . . . . . 20 Instrumentation . . . . . . . . . . . . . . 34-44 Intake Filters . . . . . . . . . . . . . . . . . 102 Intake Silencer . . . . . . . . . . . . . . . . . 19 Radiator Compartment Access Panel 31 Rail Slide Wear . . . . . . . . . . . . . . . .
INDEX S T Suspension Adjustments IQ/Switchback . . . . . . . . . . 50-57 M-10 . . . . . . . . . . . . . . . . . . 58-63 Rear . . . . . . . . . . . . . . . . . . . 50-63 Suspension Coupling, IQ . . . . . . . . . 55 Suspension Inspection, Pre-Ride . . 126 Suspension Maintenance. . . . . . . . . 126 Suspension Performance Tips. . . . . . 49 Suspension, Rear, Lubrication . . 94-95 Traction Products . . . . . . . . . . . . 66-67 Transporting the Snowmobile . . . . 129 Troubleshooting, Drive Belt. . . . . .
