WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and 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. M-10 is a trademark of Fast Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of 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.
SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 97 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.
SAFETY Operator 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 Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists E4 of a circle surrounding the letter E, followed by the 051039 distinguishing number of the country which has 0006.
SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. 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. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second.
SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Make sure the way is clear before crossing railroads and other roads and highways.
SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • • • • Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel, probe and avalanche beacon. You don’t have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected.
SAFETY Operator 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 machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.
Safety Decals and Locations SAFETY Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.
SAFETY Safety Decals and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the left console: WARNING This vehicle is designed for operator only. “NO PASSENGER” Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal on the left console. For more information on operating with a passenger, see page 13.
SAFETY Safety Decals and Locations Reverse Warning Reverse Warning Operation Warning Operation Warning Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look behind before and while backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly.
SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a Polaris dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.
FEATURES 7 8 9 6 5 4 3 10 2 1 11 12 15 13 14 1. Front Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Handlebar 6. Fuel Filler Cap 7. Operator Seat 8. Taillights 9. Storage Compartment or Cargo Bag 10. Rear Bumper 11. Snow Flap 12. Track 13. Suspension 14. Skis 15.
FEATURES 5 9 10 11 12 6 4 7 3 14 13 2 1 1. 2. 3. 4. 5. 6. 7. 8. 28 Rider Selectt Ignition Switch Handlebar hook Brake Lever MFD (Multi-Function Display) Engine Stop Switch Throttle Control Hood Hold Down Straps 8 9. Parking Brake 10. Handlebar Grip Warmer Switch 11. Thumbwarmer Switch 12. Electronic Reverse Button 13. MFD Control 14.
Cargo Area (Switchback) FEATURES + 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 Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to raise the headlight beam. Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator.
FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions. WARNING If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability.
FEATURES RIDER SELECT Adjustable Steering System Choosing the Best RIDER SELECT Position Position Riding Style 1 2 3 Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding. 4 General Trail Riding, Boondocking, 5 Deep Snow Riding Rider weight is centered on the snowmobile, providing balance, comfort and control for both novice and experienced riders. This is the recommended position for most riding situations.
FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2. Press the release button and move the handlebar forward or rearward to the desired position. WARNING Do not lubricate the RIDER SELECT mechanism.
Engine Management System FEATURES Malfunction Indicator Lamp (MIL) Illuminated MIL The MIL (Check Engine Indicator) will illuminate when a problem with engine management system components is detected. 1. Turn the engine off and restart it. If the light goes off, continued operation is permissible. 2. If the light illuminates again, determine whether engine RPM or vehicle speed is limited, then check the charts on page 34 to identify the cause.
FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost if the following conditions are encountered. Under extreme overheating conditions, the system will also stop the engine entirely to prevent engine damage.
Engine Management System FEATURES The engine management system is programmed to alert the rider when coolant temperatures reach higher-than-normal levels. The system responds by taking the following sequential steps to alert the rider. 1. The High Temperature Indicator on the MFD will flash. To cool the engine, drive the snowmobile into soft snow so that it comes into contact with the heat exchangers on the snowmobile.
FEATURES Knock Sensor A knock 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 87. Effect The knock sensor system prevents damage to the engine from detonation while developing the maximum power of the engine safely.
FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge 2 1 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 3 7 High Beam Indicator 4 5 6 7 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 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 The MFD control switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instructions are outlined on the following pages. MODE SET MFD settings can be made with the engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down, and MFD Control Switch turn the ignition key to the START position briefly to activate the gauge.
FEATURES Instrumentation MFD Settings Speedometer/Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2). To change viewing preferences, press and hold the MODE button for three seconds.
FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens. Performance Program Press and release the MODE button until the performance program screen is active.
Instrumentation FEATURES MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank. The Trip F odometer records distance traveled, and the fuel symbol continues to blink, until enough fuel is added to raise the level above 1/4 of a tank.
FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4. When the hour starts flashing, press the SET switch once to advance one hour. NOTE: Press and hold the SET button to advance the hours quickly. 5. Press and release the MODE button to save the hour. The minutes will begin flashing. 6.
Instrumentation FEATURES MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electrical system voltage level, fuel level (if equipped) and either engine coolant temperature, air temperature (accessory) or altimeter (accessory).
FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. 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. 2. Press and release the SET button until the altimeter screen is active. 3.
Instrumentation FEATURES MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the Maximum Vehicle Speed, Maximum Engine RPM and Service Interval Reminder screens.
FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated 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 engine is started (until the service reminder is reset.
Instrumentation FEATURES MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds, until the hours begin to flash. Immediately release the button. 4. Press the button again, up to five times, to advance the reminder in 50-hour increments. NOTE: The maximum interval is 250 hours. 5.
FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment. It has a red wire and a brown wire with a white stripe.
FEATURES Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the leading edge of the battery is raised away from the battery holder. Pull the battery out gently. NOTE: The battery will not come out of the holder unless the leading edge of the battery is raised. Hold the battery compartment, not the wires, while removing the battery. Pulling on the wires will separate them from the battery holder. 6. Install a new battery with fingers only. 7.
THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it.
THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving Some shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. Please see your Polaris dealer. WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment.
THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension. X NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. Tighten the straps to increase ski pressure. Loosen the straps to reduce ski pressure. Upper Nuts 1. Remove the nuts and flat washers from the upper limiter straps. 2.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear Shock Compression Damping (Premium Shocks) Turn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly, then test ride. • Turn the knob clockwise (A) for a stiffer ride. • Turn the knob counter clockwise (B) for a softer ride.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other. There are two types of rear suspension coupling.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance.
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. HIGH LOW MEDIUM To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride. Please take the time to read and understand all the possible adjustments available with this suspension.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown in the illustration. Record the measurement. 2. Have the rider sit on the snowmobile and bounce up and down on the seat a few times to set in the suspension.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments 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 (see page 67) to determine the desired FRA position. 2. To adjust, loosen the hex bolts attaching the rear lower shock cross shaft to the rail beam. 3. Using a 9/16" wrench, loosen the jam nuts on the preload bolts.
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 con3 trol. Lean toward the #4 2 setting for comfort and 1 toward the #3 setting for aggressive riding. 2.
THE PERFECT FIT FAST M-10 Rear Suspension Adjustments 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 increases ski pressure while the upper hole decreases ski pressure. Upper Lower NOTE: By design, the BIASED COUPLE design of the M-10 suspension dis- places 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 30. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. NOTE: If equipped, remove the Handlebar Cover mountain bar. 2. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).
Accessories THE PERFECT FIT Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • Voiding of warranty • Injury to self or others This applies, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.
THE PERFECT FIT Traction Products Studs Before equipping your 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 THE PERFECT FIT n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 143. 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 Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.
PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmobile.
PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. 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 129. 1/2" (1.3 cm) Brake Lever Feel If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition.
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking 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. 3 4 1 2 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indicator Lock Engagement To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.
PRE-RIDE INSPECTIONS 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 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 Start the Engine and Check n Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n 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.
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • • • • • Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank neck. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
OPERATION 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 CAUTION Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. Do not apply throttle when starting the engine unless extremely cold temperatures (below -15° F/-26° C) prevent the engine from starting.
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 on the following pages. 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 1. 2. 3. 4. Always wear eye protection when jump starting your vehicle. Keep bystanders away from the vehicles. Perform the emergency starting procedure in a well-ventilated area. Position the vehicles close enough for the jumper cables to reach easily between the batteries, but do not allow the vehicles to touch each other. 5. Lock the parking brakes on both vehicles to prevent accidental movement. 6. Open the hood and remove the left side panel. 7.
OPERATION Emergency Starting 12. Make sure that the engine stop switch is in the UP position. 13. Attempt to start the vehicle. 14. If the engine does not turn over (crank over), wait 30 to 60 seconds and attempt to start the engine again. If the engine does not start, wait another 1 to 2 minutes and attempt to start the engine again. 15. If the engine still does not start, try adjusting the clips on the jumper cable ends to ensure that they have a good electrical connections. Repeat step 14. 16.
OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). CAUTION Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended.
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.
Track Warm-Up OPERATION Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be approximately 4" (10 cm) off the ground. 2. Start the engine and allow it to warm up two to three minutes. 3. Depress the throttle abruptly and allow the track to rotate several revolutions. NOTE: It will take longer to warm up the track suf- ficiently during colder outdoor temperatures.
OPERATION n Engine Stop Switch Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to limit engine speed to 2400 RPM whenever all pressure is removed from the throttle lever and the throttle cable or throttle valves do not return to the normal closed position.
OPERATION n Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine speed limits at 2400 RPM 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 vehicle speed when operating in reverse will be approximately 12 MPH (19 km/h). 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.
Electronic Reverse (PERC 4t) OPERATION Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut off. 3. Apply the throttle slowly to make sure the snowmobile is in forward. n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 90 for more information about the engine stop 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 Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.
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 164, 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 166. 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 Item Pg Instructions (see referenced pages) Engine Stop Switch 79 79 Throttle Safety Switch 90 Test for proper operation. Do not operate if switches fail, see your dealer for service.
MAINTENANCE Item Coolant Hoses Heat Exchangers Pg --- Instructions (see referenced pages) INITIALLY Miles (km) YEARLY or EVERY Miles (km) O = Perform Service X = Replace DAILY or PRE-RIDE Periodic Maintenance Interval Table 150 (240) 500 (800) 1500 (2400) Inspect, replace if worn or damaged O O O Inspect, replace if damaged O O O Fuel Lines 118 Inspect, replace if worn or damaged O O O Battery 144 Clean terminals, test voltage O O O Track Tension 138 Verify tension, adjust
MAINTENANCE Item Engine Mounts Pg -- Instructions (see referenced pages) INITIALLY Miles (km) 150 (240) YEARLY or EVERY Miles (km) O = Perform Service X = Replace DAILY or PRE-RIDE Periodic Maintenance Interval Table 500 (800) 1500 (2400) Inspect, replace if worn or damaged O O Spark Plugs 116 Inspect condition/gap, replace as needed O O Exhaust System 120 Check muffler and pipe condition, replace damaged or missing components, clean plastic surfaces O O -- Inspect for wear, damage
MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Always change the oil filter whenever changing oil. See page 149 for the part numbers of Polaris products. Performance Synthetic 4-Stroke (PS-4) Oil Polaris recommends the use of Performance Synthetic 4-Stroke oil (PS4 or PS-4 Plus) 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). NOTE: Always check the oil level before operating a snowmobile that has tipped over.
Engine Oil MAINTENANCE n Oil Level Check NOTE: The oil level in the oil bottle may drain below the level of the dipstick if the engine has not run for more than a week. If you're not sure if there is oil in the system, you must first check to make sure oil is in the system before checking the oil level. Perform the “Oil in System Check” procedure on page 105 before performing the oil level check. 1. Position the vehicle on a level surface. 2.
MAINTENANCE Engine Oil n Oil Level Check Fill mark for oil changes (at specified coolant temperature) 8. Maintain the oil level in the safe operating range, between the upper and lower marks on the dipSafe operating range stick. If the level is low, add the recommended oil in small increments, about 2 ounces (60 ml), and recheck the level. NOTE: If the level is low, or when changing the oil, add only enough oil to bring the level to the bottom of the safe operating range on the dipstick. 9.
Engine Oil MAINTENANCE Oil in System Check 1. Position the vehicle on a level surface. Start the engine and allow it to idle 3-5 seconds (no more than 5 seconds). Turn the engine off. 2. Remove the dipstick. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. Remove the dipstick and verify that oil is present anywhere on the dipstick. 3. If oil is present, continue with the oil level check procedure beginning on page 102. 4. If oil is not present, add 1/2 quart (.
MAINTENANCE Engine Oil Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Clean the foam oil breather element with each engine oil change. See page 110. Always use the recommended oil. See page 102, 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 vehi- cle.
Engine Oil MAINTENANCE Oil Change 5. Remove the oil return hose from the oil tank. Have an assistant place the end of the hose into a drain pan. 6. Disconnect the 2-pin WHITE/RED and GREEN/WHITE starter motor solenoid control switch harness connector located near the battery. 7. Rotate the plug 90 degrees and reinstall it with the WHITE/RED wire connected. 8. Insert the male pin of the jumper harness into the starter solenoid's female port. 9. Open the handlebar cover.
MAINTENANCE Engine Oil Oil Change 18. Remove the oil filter cap, then remove the oil filter. Inspect the oring and replace it if it's worn or damaged. 19. Install a new filter, then reinstall the cap. Tighten the cap to 18.5 ft. lbs. (25 Nm). 20. Remove the jumper from the starter motor wiring harness. Reconnect the solenoid and the originally-installed harness. Reinstall the 20A EFI Fuse. 21. Remove the dipstick from the oil tank. Add 2 quarts (1.9 liters) of the recommended oil. Reinstall the dipstick.
MAINTENANCE Engine Oil Oil Change 26. Add additional oil to bring the level slightly above the lower mark (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. MODEL All OIL TO ADD AT STEP 26 Ounces 24 to 32 Milliliters 710 to 496 NOTE: Check the oil level often during the fill procedure to avoid overfilling. If the filling and checking procedure is not completed within three minutes, reinstall the dipstick.
MAINTENANCE n Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to protect sensors within the intake system from damage due to oil ingestion. Check the element before each ride. 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.
Lubrication Driveshaft Bearing MAINTENANCE Fitting 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 Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 98 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your Polaris dealer.
MAINTENANCE Lubrication Rear Suspension M-10 128 Rear Suspension + + + + IQ 121/Switchback 136 Rear Suspension + + + + + IQ 121 Shown 113
MAINTENANCE Gearcase Oil n Gearcase Oil Check Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 149 for the part numbers of Polaris products. Dipstick The dipstick is located on the lower front side of the gearcase. Maintain the oil level in the safe operating range, between the upper and lower marks on the dipstick. 1. Position the vehicle on a level surface. 2.
Gearcase Oil MAINTENANCE Gearcase Oil Change The drain plug is located on the bottom of the gearcase. NOTE: Polaris does not recommend tip- ping 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 110. 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan.
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.
Spark Plugs MAINTENANCE Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments. Wet Fouled Spark Plug The wet fouled insulator tip is black.
MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. + 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.
n Alternator Belt Inspection MAINTENANCE Inspect the alternator belt condition and tension before each ride. 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.
MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 98. 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 149 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system.
MAINTENANCE Cooling System 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. Stop the snowmobile and allow the engine to cool. Place snow on the coolers to help cool the engine. If coolant is low in the coolant overflow bottle, add coolant to the coolant bottle. Do not open the radiator pressure cap. WARNING Steam and hot liquids will cause serious burns to your skin.
MAINTENANCE Cooling System 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 mixture of antifreeze and distilled water should be added. Have your Polaris dealer perform this service. Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Maintenance Table beginning on page 98.
MAINTENANCE Cooling System Bleeding the Cooling System 3. Open the hood. 4. Remove the coolant pressure cap carefully. 5. Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck. Leave the pressure cap off. 6. With the cap off, start the engine and allow it to idle. 7. With the engine idling, observe the coolant level in the filler neck. Make sure that the coolant level in the filler neck is always visible.
Cooling System MAINTENANCE Bleeding the Cooling System 9. While observing the bleed return and making sure the coolant level is visible in the filler neck, observe the engine temperature in the digital display. The temperature should rise steadily, indicating that the system is bleeding properly. 10. If the temperature does not rise after approximately one (1) minute, repeat steps 8 and 9. Make sure steps 8 and 9 are followed precisely during the entire bleed procedure. 11.
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch Adjuster counterclockwise to move all Bolt 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 Jam nut. Nut 3. Finger tighten the adjuster bolt until it can no longer be adjusted by hand, then back off 1/4 turn. 4.
MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 75. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16" (1.5 mm). A kit is available for replacing brake pads. See your dealer. WARNING Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety.
MAINTENANCE Brakes n Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury. WARNING Keep the master cylinder cover free of dirt and debris.
MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever. During the bleeding procedure, keep the brake handle as level as possible.
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 Bulb assembly. Spring 2. Lift the rubber boot to expose the bulb. 3. Push down on the spring Harness to release it from the housing. 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 MAINTENANCE n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 156. 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. 3.
Clutch System MAINTENANCE Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the belt removal procedures. 2. Rotate the L-wrench 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.
MAINTENANCE Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication. The slide rail 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 Slack Measurement Weight Measurement Location IQ 121 Switchback 136 M-10 128 7/8"-1 1/8" (2.2-2.
MAINTENANCE Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. Adjusting Screw Lock Nut Idler Shaft Bolt If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws 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 comRails plete revolutions. Stop the engine and let the track come to a stop (do not apply brakes). 3.
MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
MAINTENANCE Steering System n Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
MAINTENANCE 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 the battery 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 149 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 Description Part No. Engine Lubricants 2874865 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) 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.
TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Probable 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 Probable 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 Probable 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 Engine Overheating Probable Cause Solution Inadequate snow conditions Stop and cool the engine. Drive into snow frequently to prevent overheating. See page 20. Low coolant Stop and cool the engine. Check the coolant level. See page 121. Check for leaks. Bleed the system if the coolant level is extremely low. Restricted air flow to radiator Stop and cool the engine. Clean snow and debris from the radiator.
TROUBLESHOOTING IQ/Switchback Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust torsion spring preload to achieve proper static sag (see page 54). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for binding suspension shafts and grease all pivot points. • Adjust torsion spring preload to achieve proper static sag (see page 54).
TROUBLESHOOTING M-10 Suspension Troubleshooting Problem Solution (Perform only one change at a time) Rear suspension bottoms too easily • Increase FRA position (see page 64). • Install appropriate optional center retainer on rear track shock (see page 65). • Increase front track shock coil spring preload by adding washers. • Revalve rear track shock compression damping (see your dealer). • Check track tension (see page 138). Rear suspension rides too stiff • Decrease FRA position (see page 64).
TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warmup 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. Riding with high RPM and slow speed (8000 RPM/ 10 MPH) Lower the gear ratio. Reduce RPM.
Service And Warranty Information WARRANTY Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
WARRANTY Service And Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2.
Limited Warranty WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty. The warranty begins on the date of purchase. This warranty is transferable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine meets current U.S. Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068.
WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use.
MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 167
MAINTENANCE LOG DATE 168 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A D Access Panel, Radiator Compartment 29 Accessories . . . . . . . . . . . . . . . . . . . . 69 Adjustable Steering System . . . . 30-32 Air Filter . . . . . . . . . . . . . . . . . . . . . 119 Alternator Belt Inspection. . . . . . . . 119 Apparel . . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 16 Drive Chain Tension. . . . . . . . . . . . 126 Driver Awareness . . . . . . . . . . . . . . . 15 Driveshaft Bearing Lubrication . . .
INDEX I R Ice and Snow Build-up . . . . . . . . . . 17 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Instrumentation . . . . . . . . . . . . . . 37-49 Intake Filters . . . . . . . . . . . . . . . . . 118 Intake Silencer . . . . . . . . . . . . . . . . . 19 Rail Slide Wear . . . . . . . . . . . . . . . . 140 Rear Rear Scissor Stop . . . . . . . . . . . 60 Rear To Front Coupling. . . . . . . . . . . 60 Relay Label . . . . . . . . . . . . . . . . . . . 131 Retainers, Optional, M-10 . . . . . .
INDEX S Suspension Performance Tips. . . . . . Suspension Set-up Chart, M-10 . . . . Suspension, Front . . . . . . . . . . . . . . . Switches Stop Switch . . . . . . . . . . . . . . . . Throttle Safety Switch . . . . . . . V 53 67 50 90 90 T Throttle Cable Lubrication . . . . . . . 111 Throttle Lever . . . . . . . . . . . . . . . 73, 91 Throttle Safety Switch . . . . . . . . 73, 90 Tip-Over Inspections . . . . . . . . . . . . 80 Torsion Spring Preload, IQ . . . . . . . . 56 Towing . . . . . . . . . . . .
