2004 PRO X Snowmobiles Owner's Manual for Vehicle Maintenance and Safety
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.
What’s the hottest thing on snow? A Polaris owner’s Web site, designed just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.
Copyright 2003 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. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
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.
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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 This section describes safe vehicle operation and identifies warning decals and their locations. Features and Controls . . . . . . . . . . . . . . . . . . .
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INTRODUCTION Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.
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 The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these numbers are essential to its recovery and identification. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs. Polaris produces high performance snowmobiles capable of traveling at high speeds. Extra caution must be observed to ensure operator safety.
SAFETY Operator Safety Stay Away From Moving Parts WARNING Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures. Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.
SAFETY Operator Safety Riding Position WARNING Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. Operating a snowmobile requires skill and balance for proper control.
SAFETY Operator Safety Excessive Speed WARNING High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They’ve been established for your protection. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels.
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 Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.
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 Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F), Polaris recommends closing the upper hood closure. WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious personal injury.
SAFETY Operator Safety Driving on Slippery Surfaces WARNING Driving on ice or hard-packed snow reduces steering and braking control, which may result in serious injury or death. Slow down and use caution. Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions. It’s dangerous to drive on ice or other slippery surfaces.
SAFETY Operator Safety Maneuverability Control and maneuverability comes not only through the steering and skis, maximum control is achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to carry a load or a passenger. Maintenance Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle.
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 Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: + Passenger Warning Polaris PRO X snowmobiles are designed for one operator only.
SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal on the lower dash.
SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English.
Safety Decals and Locations SAFETY Operation Warning AVERTISSEMENT 27
FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on the following pages. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of specific features on your machine. Accessories are available from your Polaris dealer. 1. 2. 3 4. 5 6. 7. 8. 9.
FEATURES AND CONTROLS 4 3 2 5 1 6 10 1 9 8 7 11 13 12 14 15 16 29
FEATURES AND CONTROLS 4 6 7 5 3 8 2 1 9 10 11 12 15 1. 2. 3. 4. 5. 6. 7. 8. 30 14 13 Hood Headlight Windshield Handlebar Seat Storage Compartment/Trunk Taillights Rear Bumper 9. 10. 11. 12. 13. 14. 15.
FEATURES AND CONTROLS Detonation Elimination Technology (D.E.T.) Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing. When activated, the “DETONATION FLASH” indicator (A) will flash in the lower right-hand area of the tachometer. The activated sensor reduces engine detonation by retarding the ignition timing. This results in decreased engine RPM and performance. A D.E.T.
THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page105 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming.
THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the A left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload.
THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX and Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on RydeFX or Walker/Evans shocks requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas.
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 PRO X Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the PRO X rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at X full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.
THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.
THE PERFECT FIT PRO X Rear Suspension Adjustments Clicker Shock The position sensitive clicker shock is available as an option on some models. Adjustments to the compression damping are made by turning the clicker knob (A) on the shock reservoir. Position #1 is the softest, or least compression damping. As the knob is turned to higher numbers, compression damping increases, or becomes stiffer. When adjusting, we recommend that you turn the clicker only one click at a time, then test ride.
THE PERFECT FIT PRO X Rear Suspension Adjustments Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other.
THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS.
THE PERFECT FIT PRO X Rear Suspension Adjustments Weight Transfer During Acceleration PRO X Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight 1 transfer during acceleration of the PRO X rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your tool kit to make the adjustments. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.
Handlebar Adjustments THE PERFECT FIT Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/2” wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required. 3. Adjust the handlebar to the desired angle.
THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. NOTE: The accessory tether switch is available for all models. Order PN 2870668. Use only Polaris parts and accessories on your Polaris snowmobile.
Accessories THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
THE PERFECT FIT Accessories CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8″ (2.86 cm) from outside edge of the track. CAUTION If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear. Never add shims to the wear strip.
THE PERFECT FIT Accessories Wear Strips Polaris PRO X models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories. Components as viewed from the rear of the track: 1. Top of tunnel 2. Wear strip 3. Track 4.
PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.
PRE-RIDE INSPECTIONS Before Starting the Engine Hydraulic Brakes Properly functioning brakes are critical to your safety. Always check the following A items to assure proper operation before starting the engine. Brake Lever Travel When the brake lever is squeezed, it should move no closer to the handgrip than 1/2″ (1.3 cm) (A). A distance less than this indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 93.
PRE-RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. To apply the lock, squeeze the brake handle and push forward on the brake lever lock. Hold the lock forward and release the brake handle.
PRE-RIDE INSPECTIONS Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated. Track Inspection WARNING Always inspect the track for damage before using the vehicle.
PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine. n Tether Switch: If your machine has a tether switch, make sure the engine shuts off when the tether is removed from the switch. n Lighting Check: Check the headlight (high and low beam), taillight, and brake light for normal operation.
OPERATION CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads. Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation.
OPERATION Starting the Engine Starting a Warm Engine 1. Turn key to ON. 2. Pull kill switch (shut-off switch) up to RUN. 3. Grasp starter handle and pull slowly until recoil engages; then pull to start. If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4″ open), and pull the rope with your right hand. When the engine starts, immediately release the throttle.
OPERATION Engine Break-In Oil Injection System CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately. Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are controlled by the oil pump and correspond to the engine’s RPM and throttle valve opening.
OPERATION WARNING A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck.
OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris snowmobile engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline, but a higher octane fuel (premium 91 octane) is preferred for the PRO X models. Always use the premium fuel switch when using premium fuel in your machine.
OPERATION Fuel Fuel Reserve Capacity There are approximately two gallons of fuel left in the tank when the fuel gauge indicates reserve (RES). Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol.
OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 55 for oil recommendations. When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank. If oil is not visible, continued operation may cause serious engine damage. Never mix brands of oil.
OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system.
OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. A Throttle Safety Switch Test the throttle safety switch system daily before operation.
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(s) 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. Refer to page 62 for more information about the engine stop switch and throttle safety switch.
Emergency Starting OPERATION Your machine is equipped with a tool kit containing essential tools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure. DO NOT wrap the start strap around your hand. Keep all bystanders away from the snowmobile when using the emergency starting procedure. To use the emergency start strap: 1.
OPERATION Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. S S S S Always look behind the vehicle before and while backing. Always avoid sharp turns. Shift to or from reverse only when stopped. Always apply throttle slowly. Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM.
Reverse Operation OPERATION Electronic Reverse (PERCt) Disengaging Reverse Push the yellow reverse button on the handlebar for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off. Make sure the area around your vehicle is clear and apply throttle slowly until you’re sure the machine is in forward gear.
OPERATION Towing For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions. WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used.
MAINTENANCE Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the machine. NOTE: Polaris has accessory covers and track stands available to fit all models. See your dealer for more information.
MAINTENANCE Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.
MAINTENANCE Maintenance Chart Item Weekly or before long trip Tighten idler adjusting bolt jam nuts X Check spark plug condition X 150 miles (240 km 500 miles (800 km) 1000 miles (1600 km) See Page 101 79 Inspect coolant filter, replace if necessary X X X 88 Grease ski pivots X X X 74 Grease ski spindles X X X 74 Grease center steering arm(s) X X X 74 Lubricate steering post support bracket and pivot (aerosol) X X X 74 Check cylinder base stud torque on all Polaris engin
MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.
MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service 73
MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium grease at 500 miles (800 km) and annually or about every 1000 miles (1600 km) thereafter. See page 112 for the part numbers of Polaris products. The illustration shows the location of suspension and steering components. A + indicates a grease point or fitting. S Grease the left and right spindles. Raise the front end of the machine to permit better grease entry into the spindle area.
Lubrication MAINTENANCE The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. For detailed information about suspension lubrication and adjustments, see your Polaris dealer. NOTE: The following illustrations are general representations. Your model may differ in appearance.
MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Push the clutch back onto the shaft and replace the clutch retaining bolt. Torque to 18 ft. lbs. (24.4 Nm).
MAINTENANCE Lubrication Chaincase Oil Level It’s the operator’s responsibility to check and maintain the proper chaincase oil level. To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 112 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles, then every 1000 miles or seasonally.
MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. NOTE: Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color.
MAINTENANCE Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. NOTE: These illustrations are general representations. Your model may differ. 1. Intake Foam Filter 2. Air Intake box CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction.
MAINTENANCE Variable Exhaust System (VES) Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendation chart on page 55.
MAINTENANCE Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 1000 miles (1600 km) and inspected for contamination. WARNING When draining the traps, fuel spillage will occur.
Fuel Filter/Fuel Lines Inspect the in-tank fuel filter (1) and fuel lines regularly. Give special attention to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. MAINTENANCE 1 CAUTION Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.
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.
Exhaust System MAINTENANCE Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
MAINTENANCE Engine Cooling - Liquid Cooled Models Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to water may be increased. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture.
MAINTENANCE Engine Cooling - Liquid Cooled Models Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.
MAINTENANCE Engine Cooling - Liquid Cooled Models Bleeding the Cooling System CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. If coolant becomes low in the tank, bleed the system of trapped air using the following procedure: 1. Allow the system to cool completely, then loosen the bleed screw and fill the reservoir to the FULL COLD mark.
Drive Chain Tension MAINTENANCE To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. Finger tighten the adjuster bolt (B) until it can no longer be adjusted by hand, then back off 1/4 turn. 4. Tighten the jam nut while holding the adjuster bolt. 5. The chain is now tensioned. Release the brake lever lock.
MAINTENANCE Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip (A). This A distance, called brake lever reserve, should be no less than 1/2″ (1.3 cm). Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″). A kit is available for replacing brake pads. See your dealer.
MAINTENANCE Brakes Brake Components 1 2 5 4 3 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 90, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.
MAINTENANCE Brakes Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. WARNING Keep the master cylinder cover free of dirt and debris.
Brakes 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.
MAINTENANCE Headlights Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall. 3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 2″ (5.
Headlights 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. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases 2 from the spring retainer. 2. Lift spring carefully around wire harness (2) and flip to outside of housing. 1 3. With the wire harness attached to the bulb (3), withdraw bulb from housing. 4.
MAINTENANCE Clutch System WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.
MAINTENANCE Clutch System Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. The following procedures apply to standard, electronic reverse and TEAM driven clutches. Drive Belt Removal 1. Be sure the key switch is off and the engine has come to a complete stop.
MAINTENANCE Clutch System Drive Belt Deflection A B 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”. C Drive Belt Adjustment 1. Loosen the 7/6” jam nut on the belt width adjuster. 2. Using a 1/8” Allen wrench, adjust the threaded set screw (C) as needed.
MAINTENANCE Chain Tension Maintain the proper chain tension as outlined on page 89. Oil Level Maintain the oil level between the safe marks as indicated on the oil bottle (see page 59). Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Your tool kit will contain only the tools applicable to your model. 1. Emergency Start Strap 2. Phillips Screwdriver 3. Tubular Socket 4. Tubular Socket Handle 5. Wrench 6. Screwdriver (550 PRO X) 7. Scissor Stop Wrench 8.
MAINTENANCE For Your Protection For added protection, carry the following items on your snowmobile at all times: SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner’s Manual SFirst Aid Kit 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.
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 If the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes). 10. Check track alignment (see page 102) and adjust as necessary. 11. Tighten locknuts (A). 12. Tighten idler shaft bolts (D) and torque to 35 ft. lbs. (47.5 Nm).
MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for possible damage.
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a +.
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 Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice. Check skags weekly to maintain positive steering characteristics.
Suspension Maintenance MAINTENANCE Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16″ (1.1 cm) is reached. Take the machine to your dealer for Hi-fax replacement. A A 7/16″ (1.
MAINTENANCE Suspension Maintenance Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check rear idler wheel bolts for tightness. n Check rear idler adjusting bolt locknuts for tightness. n Check front torque arm limiter strap condition.
Extended Storage MAINTENANCE Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. See page 112 for part numbers. Clutch and Drive System Remove the drive belt and store in a cool dry location. Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant. See page 112 for part numbers.
MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure: 1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3.
Extended Storage MAINTENANCE Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clockwise to OFF to shut off the fuel supply (1). Turn the valve counter-clockwise to ON to turn the fuel supply on (2). NOTE: The fuel valve is located under the hood of your machine. 1 2.
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2874439 VES II Synthetic 2-Cycle Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding Driven clutch malfunction Solution -Disassemble drive clutch to inspect shift weights for wear and free operation. SEE YOUR DEALER. -Clean and polish stationary shaft hub. -Replace ramp buttons and rollers. SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Broken drive clutch components -SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft -SEE YOUR DEALER. Drive belt surface flat spots Poor low RPM performance Engine doesn’t turn Engine requires more than normal pulls to start 114 Solution -Inspect and replace if necessary. Drive chain loose or worn, sprocket teeth broken -Inspect and adjust or replace.
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause Faulty ignition No fuel to engine Flooded engine (normal situation caused by too much choking) Solution -Remove spark plug(s) and replace with new plug(s). If engine still fails to start, check for spark; if no spark SEE YOUR DEALER. -Make sure the fuel valve is “ON”. Check tank level and fill up with correct fuel. -Ice in fuel line, filter, or pump.
TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily -Increase torsion spring preload -Increase rear shock compression damping by turning screw clockwise -Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning screw counterclockwise (if equip
Belt Troubleshooting TROUBLESHOOTING Belt Wear/Burn Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you.
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 Warranty Coverage and Exclusions 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.
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 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.
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . 44-47 Air Box . . . . . . . . . . . . . . . . . . . . . . . . 23 B Bearings . . . . . . . . . . . . . . . . . . . . . . . 109 Before Starting the Engine . . . . . . . 48-51 Belt Troubleshooting . . . . . . . . . . . . . 117 Bleeding the Cooling System . . . . . 67-88 Bleeding the Hydraulic Brake System . 93 Brake Components . . . . . . . . . . . . . . . . 91 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . 92 Brake Lever Travel . . . . .
INDEX J S Jackshaft Bearing Greasing . . . . . . . . . 76 Jetting Guidelines . . . . . . . . . . . . . . . . . 61 SAFETY . . . . . . . . . . . . . . . . . . . . . 10-27 Safety Decals and Locations . . . . . 23-27 Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Scissor Stop . . . . . . . . . . . . . . . . . . 40-41 Service Contract . . . . . . . . . . . . . . . . . 122 Shock Absorber Components . . . . . . . . 33 Shock Spring Preload, Front . . . . . . . . 34 Shock Valving . . . . . . . . .
INDEX T W Track Maintenance . . . . . . . . . . . 101-103 Track Tension . . . . . . . . . . . . . . . . . . . 101 Track Tension Data . . . . . . . . . . . . . . 101 Track Warm-Up . . . . . . . . . . . . . . . . . . 56 Traction Products . . . . . . . . . . . . . . . . . 45 Transporting the Snowmobile . . . . . . 111 TROUBLESHOOTING . . . . . . . 113-117 Warning Labels . . . . . . . . . . . . . . . 23-27 WARRANTY . . . . . . . . . . . . . . . 118-123 Water Pump Belt Inspection . . . . . . . . .
For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No.
