WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on which they operate.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 This section describes safe vehicle operation and identifies warning decals and their locations. Features . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when 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.
Operator Safety SAFETY Follow the recommended maintenance program outlined beginning on page 87 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.
SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death.
Operator Safety SAFETY Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control. WARNING Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.
SAFETY Operator 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. Always wear an approved helmet and eye protection. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills.
Operator Safety 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. WARNING Control becomes more difficult with two people on board.
SAFETY Operator Safety Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. 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 snowmobile 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 Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche beacon. You don’t have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected.
Operator Safety SAFETY Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your snowmobile, 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 on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.
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 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 snowmobile. 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 snowmobile and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed in MPH Actual Thermometer Reading (°F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 -20 -34 -41 -45 -48 -51 -53 -55 -57 -58 -60 -61 -62 -25 -30 -40 -46 -47 -53 -51 -58 -55 -61 -58 -64 -60 -67 -62 -69 -64 -71 -65 -72 -67 -74 -68 -75 -69 -76 5 min.
Safety Decals and Locations SAFETY Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.
SAFETY Safety Decals and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the console below the steering post: Warming This vehicle is designed for operator only. “NO PASSENGER” + Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal at the right side of the steering post. For more information on operating with a passenger, see page 13. Warming This vehicle is designed for operator and “ONE” passenger only.
SAFETY Safety Decals and Locations + + Reverse Warning Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: S S S S Look behind before and while backing. Avoid sharp turns. Shift to or from reverse only when stopped. Apply throttle slowly. NOTE: For more information, see Owner’s Manual. If electric reverse: S Machine stopped and engine at idle, push yellow button on LH control to reverse.
SAFETY Safety Decals and Locations Operation Warning S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is missing, contact a Polaris dealer for a + + replacement. S This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.
FEATURES 4 10 9 11 8 7 5 6 3 12 2 13 1 14 15 18 16 17 1. 2. 3. 4. 5. 6. 7. 8. 9. Front Bumper Hood Headlight Passenger Lumbar Adjuster (Touring) Windshield Handlebar Operator Seat Passenger Seat (Touring) Passenger Grab Handle 10. Grab Handle Heater Switch (Touring) 11. Trunk Cover or Storage Compartment 12. Taillights 13. Rear Bumper 14. Snow Flap 15. Track 16. Suspension 17. Skis 18.
FEATURES 16 6 7 8 5 4 9 10 11 12 13 3 15 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 28 14 1 Fuel Filler Cap Rider Selectt Ignition Switch Handlebar hook Brake Lever MFD (Multi-Function Display) Engine Stop Switch Throttle Control Hood Hold Down Straps 10. Parking Brake 11. Handlebar Grip Warmer Switch 12. Thumbwarmer Switch 13. Electronic Reverse Button 14. MFD Control 15. Headlight Dimmer Switch 16.
FEATURES Passenger Seat (Touring) The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob (A). A Storage Compartments Trunk (Touring) Open the trunk cover (B) to access the rear storage compartment. The passenger seat and trunk cover are removeable to provide open storage for transporting larger items. B 1. Remove the trunk cover. C 2. Push down on the seat latch lever (C), which is located at the lower rear of the passenger seat. 3.
FEATURES Radiator Compartment Access Panel The access panel (+) is provided for cleaning debris from the radiator. + Cargo Rack (Switchback) The maximum weight capacity for the cargo rack (+) is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit. Do not allow a passenger to sit on the seat back or the cargo rack. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right.
FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. 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 Adjusting RIDER SELECT 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.
Engine Management System FEATURES Malfunction Indicator Lamp (MIL) The MIL (Check Engine Indicator) will illuminate when the ECU detects a problem with engine management system components. If this occurs, see your dealer for service immediately. The MIL will blink in the event that the ECU detects an error with the turbo boost regulation system.
FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (FST) if the following conditions are encountered.
Engine Management System FEATURES Engine Overheats (FS) Indication Flashing g overheat h lamp l Flashing g overheat h lamp l with engine g misfire At Vehicle Speed At Engine MPH (km/h) ° F (° C) 0-31 (0-50) 230 (110) Explanation Temp 32-46 (51-74) 230-221 (110-105) 47-62 (75-100) 221-212 (105-100) Above 62 (100) 212 (100) 0-31 (0-50) 239 (115) 32-46 (51-74) 239-230 (115-110) 47-62 (75-100) 230-221 (110-105) Above 62 (100) 221 (105) Lamp p flashes when engine i temperature exceeds
FEATURES Detonation Elimination Technology (DET) (Turbo Models) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. NOTE: Engine performance will be reduced if fuel with a lower octane than 91 is used. See fuel recommendations on page 79. Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely.
FEATURES Instrumentation MFD Component Identification Item 2 1 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 3 4 7 High Beam Indicator 5 6 7 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 1 2 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers per hour RPM - Engine crankshaft revolutions per minute 4 Air Temp (if equipped) Engine
FEATURES Instrumentation MFD Settings MFD settings can be made with the A engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge. The gauge will illuminate for about 90 seconds. Use the MFD Control Switch (A) to set B C the MFD display to your preference. The rocker switch has a MODE button (B) and a SET button (C). Standard vs.
Instrumentation FEATURES 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 38.
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 Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement. When “ALt” displays, the program is in the metric mode. 1. Enter the Engine Program and select the altimeter display. 2. Press and hold the SET button for five seconds. 3.
FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed.
Instrumentation FEATURES 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.
FEATURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn’t A 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 B compartment (A). 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.
Instrumentation FEATURES MFD Battery Replacement 6. Install a new battery with fingers only. 7. Seal the end of the battery compartment using high strength double-sided 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. Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located.
THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT IQ Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness + of ArvinMeritor MPV Select shocks can be made by turning the adjustment screw (+) located near the base of the shock. This adjustment is the easiest to perform and it should be considered first. The factory setting for this shock is the softest position, with the adjusting screw all the way out (counterclockwise).
THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving (Switchback) The shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. 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 snow-cross racing would provide a very stiff ride on the trail.
THE PERFECT FIT Switchback Rear Suspension Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the suspension.
THE PERFECT FIT Switchback Rear Suspension 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. C A B A. Soft Tension - long end of cam to front B. Medium tension - short end of cam up C.
THE PERFECT FIT Switchback Rear Suspension Rear Track Shock Compression Damping A. Turn rear track shock screw clockwise to stiffen compression. B. Turn the rear track shock knob clockwise for a softer ride. C. Turn the rear track shock knob counter clockwise for a stiffer ride.
THE PERFECT FIT Switchback Rear Suspension Rear Shocks When adjusting, we recommend that you turn the adjuster slightly, then test ride. The recommended setting for this shock is eight (8) clicks counter-clockwise. FOX Zero Pro XC Shock The FOX Zero Pro XC shock is standard on the Switchback model. Turn the adjustment knob (L) on the shock reservoir to make adjustments to the compression damping.
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 3. Subtract Y from X and you will have the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). The correct amount of SAG for the FAST M-10 rear suspension is 3-4 inches (8-10 cm). If the measured sag is incorrect, adjust the FRA position and rear spring preload. See pages 56--57.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments 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 (located under the hood of your snowmobile or on page 59) to determine the desired FRA position. 2. To adjust, loosen the hex bolts (A) attaching the rear lower shock cross shaft to the rail beam. 3.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments 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 Static Sag and Ride Height Settings 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 3 control. Lean toward the #4 setting for comfort 2 and toward the #3 1 setting for aggressive riding. 2.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (A) increases ski pressure while the upper hole (B) decreases ski pressure. NOTE: B A By design, the BIASED COUPLE design of the M-10 suspension displaces the rear arm as the front arm is compressed.
THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 31. Use the following steps to adjust handlebar angle at the handlebar block. C 1. Remove the handlebar cover (A) to expose the handlebar and the four adjuster block bolts (B). NOTE: If equipped, remove the mountain bar (C). 2. Using a 7/16″ (11 mm) wrench, loosen the four nuts (D) on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).
THE PERFECT FIT Passenger Grab Handle Adjustment (Touring) On some Touring models the position of the passenger grab handles can be adjusted for rider preference. To make an adjustment: 1. Unscrew and remove the knob assemblies (A) that secure the grab handles. 2. Reposition the grab handles to one of the three available positions on the grab handle tube between the operator seat and the passenger seat. 3. Reinstall the knob assemblies and tighten securely.
THE PERFECT FIT Traction Products Studs Before equipping your snowmobile 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 n Carbide Skags THE PERFECT FIT 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 127. If your snowmobile 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 Check Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience. n Throttle Lever The throttle and brake are the primary controls of your snowmobile.
PRE-RIDE INSPECTIONS Check 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 Check Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. 1/2″ (1.3 cm) Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 113. Lever Feel If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition.
PRE-RIDE INSPECTIONS Check Before Starting the Engine n Park Brake Lever Lock Use the park brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. A. Brake Lever C B D B. Park Brake Lever Lock A C. Master Cylinder Reservoir / Cover D. Fluid Level Indicator Lock Engagement To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.
PRE-RIDE INSPECTIONS Check Before Starting the Engine n Track Inspection WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. Use of traction products such as studs increases the possibility of track damage and/or failure.
PRE-RIDE INSPECTIONS Check Before Starting the Engine n Suspension Inspection 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.
PRE-RIDE INSPECTIONS Check After Starting the Engine n Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.
PRE-RIDE INSPECTIONS n Tip-Over Inspections In the event of a tip-over or rollover, check the oil level before operating the snowmobile. CAUTION Failure to check the oil after a tip-over can result in serious engine damage. Always check the oil level before operating a snowmobile that has tipped over or rolled over. NOTE: In the event of a tip-over or rollover, the engine will stop. To restart the engine, turn the key to the OFF position, then restart.
Fuel Safety OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill the tank neck. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
OPERATION Break-In Period The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. CAUTION Excessive heat build-up during the first 500 miles (800 km) of operation will damage close-fitting engine parts.
Starting the Engine OPERATION WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 65. Do not depress the throttle until the engine starts. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position.
OPERATION Emergency Starting If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions below. WARNING Improperly connecting or disconnecting jumper cables can result in an explosion and cause serious injury or death. When connecting jumper cables, always connect the negative (usually black) cable last.
Emergency Starting OPERATION 8. Pull back the red plastic boot covering the positive terminal of the weak battery. Connect one end of the positive jumper cable to the positive terminal of the weak battery. 9. Connect the other end of the positive jumper cable to the positive terminal of the charged battery. NOTE: Make sure that the end of the negative cable by the weak battery is not contacting the snowmobile battery or chassis. 10.
OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
Fuel OPERATION For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended. Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank. Do not allow the snowmobile to run out of fuel.
OPERATION n Engine Stop Switch L Push down on the engine stop switch (L) to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN 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.
n Throttle Lever OPERATION WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. Turn the ignition switch to OFF. 2. Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate. 3.
OPERATION Electronic Reverse (PERC 4t) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum engine speed when operating in reverse will be 6000 RPM. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed.
n Emergency Stopping OPERATION The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 80 for more information about the engine stop switch and throttle safety switch.
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 4″ (10 cm) off the ground. Remove the key and cover the snowmobile. Towing WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope.
Emission Control Information MAINTENANCE 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.
MAINTENANCE Emission Control Information Owner’s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 147, 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 149. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1500 miles (2400 km).
MAINTENANCE Periodic Maintenance Interval Table DAILY or PRERIDE D = Perform Service " = Replace Item Pg Instructions (see referenced pages) Engine Stop Switch 71 Ignition Switch 71 Throttle Safety Switch 80 Taillight 71 Brakelight 71 Headlight 71 D Skags (Wear Bars) 127 Inspect for wear or damage, replace when worn D Test for proper p p operation. p Do not operate if switches fail, fail see your dealer for service.
MAINTENANCE Periodic Maintenance Interval Table DAILY or PRERIDE D = Perform " = Replace Item INITIALLY mi (km) 150 500 (240) (800) YEARLY or EVERY mi (km) Pg Instructions (see referenced pages) Coolant Hoses - Inspect, replace if worn or damaged D D D Heat Exchangers - Inspect, replace if damaged D D D Throttle Lever 65 81 D D D Fuel Lines 103 Inspect, replace if worn or damaged D D D Clean terminals, test voltage D D D Track Alignment 124 Verify alignment, adjust as ne
MAINTENANCE Periodic Maintenance Interval Table DAILY or PRERIDE D = Perform " = Replace Item Engine Mounts Pg Instructions (see referenced pages) - Inspect, replace if worn or damaged INITIALLY mi (km) 150 500 (240) (800) YEARLY or EVERY mi (km) 1500 (2400) D D Spark Plugs 102 Inspect condition/gap, replace as needed D D Exhaust System 105 Check muffler and pipe condition, replace damaged or missing components, clean plastic surfaces D D - Inspect for wear, damage and proper routing
Engine Oil MAINTENANCE Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Always change the oil filter whenever changing oil. See page 133 for the part numbers of Polaris products. Performance Synthetic 4-Stroke (PS-4) Oil Polaris recommends the use of Performance Synthetic 4-Stroke (PS-4) 0W50 oil for this engine. PS-4 has been specially formulated for use in Polaris 4-cycle snowmobile engines.
MAINTENANCE Engine Oil n Oil Level Check NOTE: Read the entire oil check procedure before checking the oil level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. To obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant temperature must be between 145 and 160 degrees F. (63-71 degrees C). Never add or remove oil if the engine coolant temperature is not within the specified range.
Engine Oil n Oil Level Check MAINTENANCE 6. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. 7. Remove the dipstick and view the oil level. NOTE: The oil level reading will be accurate for only one to three minutes after turning off the engine. If the oil check isn’t completed within three minutes, reinstall the dipstick. Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank. A.
MAINTENANCE Engine Oil Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Clean the foam oil breather element with each engine oil change. See page 97. Always use the recommended oil. See page 91, or see your Polaris dealer about oil change kits, which contain a new filter and the recommended oil. NOTE: A special jumper harness is required for changing the oil on this vehicle.
Engine Oil MAINTENANCE Oil Change 9. Open the handlebar cover. Locate the connector with the BROWN and RED/WHITE wires. Connect the BROWN wire from the jumper harness to the BROWN wire on the handlebar harness by inserting the harness plug into the handlebar wiring harness connector. 10. Open the fuse box and remove the 20A EFI fuse from the fuse block. 11. Reinstall the left side panel. 12. Have an assistant use the ignition key to turn over the engine. Crank the engine for 15 seconds. 13.
MAINTENANCE Engine Oil Oil Change 22. Make sure the engine coolant temperature is between 145 and 160 degrees F. (63-71 degrees C). If necessary, start the engine and allow it to idle until the coolant temperature is within the specified range. 23. Remove the dipstick from the oil tank. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. 24. Remove the dipstick and view the oil level. A. Fill mark for oil changes (at specified coolant temperature) B.
Foam Oil Breather Element MAINTENANCE The foam oil breather element absorbs small amounts of liquid to protect sensors within the intake system from damage due to oil ingestion. Clean or replace the breather element at each engine oil change. Clean the element if the snowmobile has been tipped on its left side three times, either during service or while riding, as oil may leak into the element. CAUTION Operating the snowmobile with a clogged foam oil breather element can result in severe engine damage.
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. + Front Suspension The front suspension and steering components do not require lubrication.
MAINTENANCE Lubrication M-10 136 Rear Suspension L L L L Switchback Rear Suspension L L L L L 99
MAINTENANCE Lubrication n Gearcase Oil Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 133 for the part numbers of Polaris products. The dipstick (A) is located on the lower front side of the gearcase. Maintain the oil level in the safe operating range (B), between the upper and lower marks on the dipstick. A Oil Check 1. Position the vehicle on a level surface. 2.
Lubrication MAINTENANCE Gearcase Oil Oil Change The drain plug (A) is located on the bottom of the gearcase. NOTE: Polaris does not recommend tipping the snowmobile onto it’s side for service. Any time the snowmobile is tipped onto it’s left side, always check the oil level and clean the foam oil breather element. See page 97. 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely NOTE: 3. 4. 5. 6.
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. CAUTION Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile.
Intake Filters MAINTENANCE + 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. Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump.
MAINTENANCE Alternator Belt Inspection Inspect the alternator belt condition and tension at the intervals outlined in the Periodic Maintenance Table beginning on page 88. 1. Stop the engine. 2. Open the hood. 3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, install a new belt. 4. Grasp the alternator belt and attempt to twist it. 5. If the belt rotates 1/4 turn (90 degrees) or more (as shown), tighten the belt or install a new belt.
Exhaust System MAINTENANCE Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 88. 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. Allow the engine and exhaust system to cool completely. 2. Open the hood. 3. Inspect the muffler and pipes for cracks or damage.
MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 133 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system.
Cooling System MAINTENANCE Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your snowmobile after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service. Add coolant if the level is low.
MAINTENANCE Cooling System Bleeding the Cooling System WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. 1. Read the entire coolant bleed procedure before beginning. After beginning the bleed procedure, do not stop the engine until reaching step 14. 2. Move the snowmobile into a well-ventilated area. Allow the engine to cool completely.
Cooling System MAINTENANCE Bleeding the Cooling System 8. With the engine idling, and while making sure that the level in the filler neck remains visible, observe the bleed return. If the system is self-bleeding properly, coolant will be pumped out of this hole. NOTE: Coolant flow may be erratic (spitting, misting) for the first few minutes of bleeding, but as long as the procedure is followed and coolant is visible in the filler neck, the system should bleed properly. 9.
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (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.
Brakes n Hydraulic Brake Inspection MAINTENANCE Inspect the brake lever reserve before each use of the snowmobile. See page 67. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16″ (1.5mm). 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 WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury. WARNING Keep the master cylinder cover free of dirt and debris.
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 Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum covering from the headlight assembly. B 2. Lift the rubber boot to expose the bulb. C 3. Push down on the spring (A) to release it from the housing. A 4.
MAINTENANCE Electrical System RELAY LABEL FUSE LABEL Ground side of start solenoid START SOLENOID RELAY CHASSIS RELAY SPARE 20A ACCESSORY EMERGENCY SPARE 30A CHASSIS 30A EX.
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 snowmobile until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer.
Clutch System n Drive Belt Condition MAINTENANCE Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 140. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile.
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. 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility, make sure the clutch tool access hole (+) is visible between the 11:00 and 2:00 positions of the clutch sheave. 2. Turn the ignition key off. Wait for the engine to come + to a complete stop.
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 counter-clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves. 3.
MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size recommended for your model. See your Polaris dealer. CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model. Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death.
Track Lubrication MAINTENANCE 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 requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication.
MAINTENANCE Track Tension 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 adjustment is critical for proper handling. Always maintain correct tension and alignment. Track Tension Data Chart Suspension Weight Switchback 10 lbs. (4.
MAINTENANCE Track Tension 4. Check for specified slack (C) between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A). B 10 lbs. (4.5 kg) A D C 7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on the other side of the track. NOTE: Check more frequently when the snowmobile is new. 9.
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 snowmobile 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.
Steering System MAINTENANCE Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
Steering System n Ski Skags MAINTENANCE WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. 2. 3. 4. 5. Remove the left side panel. Disconnect the battery hold-down strap. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last.
Battery MAINTENANCE Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until thebattery voltage is 12.8 or greater. NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.
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 133 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 Engine Protection Fogging the engine is not recommended for this model. CAUTION Fogging the engine improperly can result in damage to the sensors. Fogging is not recommended. Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage.
POLARIS PRODUCTS Part No. Description 2874865 2874866 Engine Lubricants Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt.) Performance Synthetic 4-Stroke (PS-4) 0W 50 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 and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Possible Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 34. Jammed clutch Check for twisted belt or broken spring. See your dealer. Jammed track Remove any foreign objects. Slider may be melted to the track clips due to lack of lubrication. Track may be iced up or frozen to the ground. Jammed or broken chaincase sprocket or chain See your dealer.
TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Refuel. Water is present in fuel See your dealer. Old or non-recommended fuel Replace with fresh recommended fuel. Fouled or defective spark plugs Inspect plugs and replace if necessary. No spark to spark plug See your dealer. Water or fuel in crankcase See your dealer. Clogged fuel filter Replace the filter. Low battery voltage Recharge the battery to 12.8 VDC.
TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Possible Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 34. Low battery voltage Recharge the battery to 12.8 VDC. Water is present in fuel See your dealer. Poor quality or low octane fuel Replace with fresh recommended fuel. Loose ignition connections Check all connections and tighten.
TROUBLESHOOTING Engine and Drive Train Troubleshooting Harsh Drive Clutch Engagement Possible Cause Solution Worn drive belt Replace with the recommended belt. Excessive belt/sheave clearance See your dealer. Drive Belt Turns Over Possible Cause Solution Incorrect belt Replace with the recommended belt. Incorrect clutch alignment See your dealer. Broken or loose engine mount See your dealer. Drive System Noise Possible Cause Solution Broken drive clutch components See your dealer.
TROUBLESHOOTING Suspension Troubleshooting (Switchback) Problem Solution (perform only one change at a time) Rear suspension bottoms too easily S Verify sag dimension (see page 50). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. S Increase shock compression damping (see page 53). Rear suspension rides too stiff S Check for binding suspension components and grease all pivot points. S Verify sag dimension (see page 50).
TROUBLESHOOTING Suspension Troubleshooting (M-10) Problem Solution (perform only one change at a time) Rear suspension bottoms too easily S Increase FRA position (see page 56). S Install appropriate optional center retainer on rear track shock (see page 57). S Increase front track shock coil spring preload. S Revalve rear track shock compression damping (see your dealer). S Check track tension (see page 122). Rides too stiff in rear S Decrease FRA position (see page 56).
TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM S Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm-up S Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM S Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
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 Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty. The warranty begins on the date of purchase. This warranty is transferrable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
WARRANTY Exported Vehicles 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) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi.
MAINTENANCE LOG DATE 150 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 151
INDEX A Accessories . . . . . . . . . . . . . . . . . . . . Adjustable Headlights . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . Alternator Belt Inspection . . . . . . . . Avalanches . . . . . . . . . . . . . . . . . . . . D 61 30 104 104 16 B Battery . . . . . . . . . . . . . . . . . . . 128-130 Battery Charging . . . . . . . . . . . . 129-130 Battery Installation . . . . . . . . . . . . . 128 Battery Jumping . . . . . . . . . . . . . . 76-77 Battery Removal . . . . . . . .
INDEX F Fuel Lines . . . . . . . . . . . . . . . . . . . . Fuel Pump . . . . . . . . . . . . . . . . . . . Fuel Safety . . . . . . . . . . . . . . . . . . . . Fuel System Deicers . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . O 103 103 73 79 115 G Gauge Cleaning . . . . . . . . . . . . . . . . 45 Gearcase Oil . . . . . . . . . . . . . . . 100-101 Grab Handle Adjustment . . . . . . . . . 61 H Halogen Bulbs . . . . . . . . . . . . . . . . Handlebar Adjustments . . . . . . .
INDEX S T Skags . . . . . . . . . . . . . . . . . . . . . . . . 63 Ski Alignment . . . . . . . . . . . . . . . . . 126 Ski Pressure, M10 . . . . . . . . . . . . . 58-59 Ski Skags . . . . . . . . . . . . . . . . . . . . 127 Slide, Rail . . . . . . . . . . . . . . . . . . . . 124 Snow Conditions . . . . . . . . . . . . . . . 20 Spark Plugs . . . . . . . . . . . . . . . . . . . 102 Spring Preload . . . . . . . . . . . . . . . . . 50 Starting the Engine . . . . . . . . . . . . . . 75 Starting, Emergency . . .
