Pantone 426C Trail RMK Snowmobile Owner's Manual for Maintenance and Safety
Pantone 426C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No.
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris 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. Copyright 2009 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 and Controls . . . . . . . . . . . . . . . . . . .
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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. When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips.
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, indicates the potential for serious injury. WARNING A WARNING indicates a potential hazard that may result in serious injury or death.
Operator Safety SAFETY Follow the recommended maintenance program beginning on page 65 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. 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 Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment that’s appropriate to the conditions you may encounter.
SAFETY Operator Safety Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22. WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
Operator Safety SAFETY Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death.
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. The noise of your machine will drown out the sound of approaching vehicles.
Operator Safety SAFETY Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. You don’t have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected.
SAFETY Operator Safety Ice and Snow Build-up 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, check for ice and snow build-up that may be obstructing the steering linkage. Snow screens and bib kits are available through your dealer to help reduce snow and ice build-up. WARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death.
Operator Safety SAFETY Driving in Hilly Terrain WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.
SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine’s compression to help slow the machine and keep it from rolling freely downhill. WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure.
Operator Safety SAFETY 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. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
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 machine. NOTICE: Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine. Do not drive for prolonged periods on blacktop, gravel, or ice.
Operator Safety SAFETY Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.
SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.
SAFETY Safety Decals and Locations Track/Seat Warning + The track/seat warning decal is on the rear of the tunnel: WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. 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.
Safety Decals and Locations SAFETY 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 AND CONTROLS 4 5 6 7 3 8 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. See your Owner’s Manual Supplement. Tip: Accessories are available from your Polaris dealer. 1. Headlight Dimmer Switch 2. Parking Brake Lock 3. Handlebar Grip Warmer Switch 4. Thumbwarmer Switch 5. Electronic Reverse Button 2 3 4 5 1 Fuel Valve The fuel valve is located under the hood.
FEATURES AND CONTROLS 4 6 5 7 3 2 1 8 13 9 10 11 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and regrease all suspension parts before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT Front Suspension Adjustments WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Always verify ski alignment before making adjustments to the IFS. See page 98 to check alignment. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. The tension at which the shock coil spring is set is called spring preload.
THE PERFECT FIT Front Suspension Adjustments Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.
THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload.
THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail.
THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) X Y To set up the EDGE RMK rear suspension torsion spring preload, measure the distance between the ground and rear bumper (see illustration). This measurement should be taken with no rider and the rear suspension at full extension. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.
THE PERFECT FIT 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). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration for reference. The ideal amount of Sag for the this rear suspension is four inches (X-Y=4).
THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.
THE PERFECT FIT Rear Suspension Adjustments Shock Compression Damping Your snowmobile is equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. 1. Locate the adjustment screw near the base of the shock. 2. Adjust the screw 1/2 turn clockwise to increase compression valving and stiffen the ride. Test ride the snowmobile before making further adjustments. Tip: An excessive adjustment can result in damage to the shock.
THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and Cover the four adjuster block bolts. 2. Using a 7/16-inch wrench, loosen the four nuts on the Bolts bottom of the adjuster block (turn the handlebar either left or right for access to the rear nuts). If necessary, pry the blocks apart with a screwdriver. 3. Adjust the handlebar to the desired angle.
Accessories THE PERFECT FIT Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. Use only Polaris parts and accessories on your Polaris snowmobile.
THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTICE: Installing studs on models without wear strips will result in damage to the cooler or tunnel. Always ensure that wear strips are installed before installing studs. See your dealer for more details.
Traction Products 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. The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control. Similarly, if your machine is equipped with carbide skags or if you’re adding them, it may be necessary to add track studs to maintain proper vehicle control.
THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel or cooler damage, wear strips must be installed whenever track studding is used. See your dealer for more information. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories. NOTICE: Never add shims to the wear strip. Track damage will result due to lack of clearance between upper carrier wheels and track. Components as viewed from the rear of the track: 1.
Pre-Ride Checklist PRE-RIDE INSPECTIONS Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages.
PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.
PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 1/2 inch (1.3 cm) cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. See pages 82-83 or see your dealer for service.
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a 3 4 2 parking brake lever lock located over the brake lever. Use the 1 brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4.
PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System WARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
PRE-RIDE INSPECTIONS 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 Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating. n Mirrors (if equipped) Adjust the mirrors so they can be used to their full advantage. n Operating Area Before driving, check your surroundings.
Starting the Engine OPERATION NOTICE: 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 fuel valve on. See page 27. 2. Turn the key to the ON position. 3. Pull the engine stop switch up to the RUN position. 4. If starting a cold engine, flip the choke toggle to FULL CHOKE. Do not use the choke if starting a warm engine.
OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in. NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts.
Engine Break-In OPERATION Oil Injection System Always check and fill the oil tank when refueling. See page 55. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately. Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of Premium 2-Cycle Oil for this engine.
OPERATION Track Warm-Up WARNING! Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile. 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.
Slide Rail and Track Cooling OPERATION NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads. Fuel WARNING! Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.
OPERATION Fuel Fuel Recommendations Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85).
n Oil Low Oil Indicator Light OPERATION The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. If oil is not visible, continued operation may cause serious engine damage. Add oil before further operation of the snowmobile. See page 51 for oil recommendations. Low Oil Level Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage.
OPERATION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters.
Carburetion OPERATION Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. RMK carburetors are preset to operate at altitudes of 6000-8000 feet (1800-2400 m) above sea level (see page 78 for more information).
OPERATION n Engine Stop Switch Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. Stop Switch 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 carburetor(s) to determine what caused the safety switch to activate. 3.
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 58 for more information about the engine stop switch and throttle safety switch.
Electronic Reverse (PERCt) OPERATION Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described on page 62. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse. WARNING! Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.
OPERATION Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: 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. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off. 3.
Towing OPERATION 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. For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions. WARNING! Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death.
MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang tag. These items are required by U.S. Environmental Protection Agency regulations.
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 124. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).
MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Lubrication Front Suspension Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 109 for the part numbers of Polaris products. The illustration shows the location of suspension and steering components. A + indicates a grease point or fitting. • Grease the left and right spindles. Raise the front end of the machine to permit better grease entry into the spindle area.
Lubrication MAINTENANCE Rear Suspension The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. For detailed information about suspension lubrication and adjustments, see your Polaris dealer. Tip: The following illustrations are general representations. Your model may differ.
MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fitting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal (approximately two pumps). + Throttle Cable Lubricate the throttle cable lightly with grease or oil.
Lubrication MAINTENANCE n Chaincase Oil Level Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 66. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil. Polaris recommends the use of Polaris Synthetic Chaincase Lube.
MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
Spark Plugs MAINTENANCE Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color.
MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. These illustrations are general representations.
Carburetor MAINTENANCE Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination. WARNING! When draining the traps, fuel spillage will occur.
MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly.
Fuel Filter/Fuel Lines MAINTENANCE The fuel filter is located inside the fuel tank. This component requires no maintenance. Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly. NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines.
MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 45. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch/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 Brake Fluid WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. The brake fluid level can be seen through a plastic sight glass in the brake reservoir.
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 Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall. 3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed two (2) inches (5.
MAINTENANCE Lights NOTICE: Avoid touching 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. Removing Halogen Bulbs 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer. 2. Lift spring carefully around wire harness (2) and flip to outside of housing. 3.
MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. NOTICE: If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer.
Clutch System MAINTENANCE n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. See Belt Troubleshooting on page 111. Periodically check the condition and tension of the drive belt, and always carry a spare.
MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTICE: 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. 2. Turn the ignition key off. Wait for the engine to stop completely. 3. Lock the parking brake (if equipped). 4. Open the hood. 5. Remove the clutch guard retaining pin and open the clutch guard. 6.
Clutch System MAINTENANCE Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: 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. Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves. 3.
MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). 1 2 Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft. 1. Loosen the 7/16-inch jam nut on the belt width adjuster. 2.
Clutch System MAINTENANCE Torque Stop Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010-.030 inch (.25-.75 mm) from the engine case. Adjust if necessary, and lock the jam nut. .010-.030 in. (.25-.75 mm) Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. Chain Tension Maintain the proper chain tension as outlined on page 80.
MAINTENANCE Track Track Inspection WARNING! Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand to check for possible damage. 3. Carefully examine the track along the entire length of each rod (+). Bend the track to check for breakage. 4.
Track MAINTENANCE Track Lubrication WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication. The slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication.
MAINTENANCE Track WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber.
Track MAINTENANCE Track Tension If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track. 9. Repeat the measurement on the other side of the track. Tip: Check more frequently when machine is new. Slack Measurement Locknut Adjusting Screw Idler Shaft Bolt Track 16 in. (40 cm) 10 lbs. (4.54 kg) 10.
MAINTENANCE Track n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop Rails the engine and let the track come to a stop (do not apply brakes). 3.
MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the illustration.
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 MAINTENANCE n Ski Skags 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. WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. Replace skags as recommended.
MAINTENANCE Suspension Maintenance n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or rails.
Battery MAINTENANCE WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, open flames, cigarettes, etc. away.
MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Battery MAINTENANCE Battery Installation WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. Attach the hold down strap. 3. Install the battery vent tube.
MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter): • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly. • Have the battery tested and recharged before reinstalling it in the vehicle. If a battery with a low charge freezes, the cells could be damaged. Always maintain a full charge on a stored battery. See the table below.
Daily Storage MAINTENANCE 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 inches (10 cm) off the ground. Remove the key and cover the machine. Tip: Polaris has accessory covers and track stands available to fit all models. See your dealer for more information.
MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. 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.
Extended Storage MAINTENANCE Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure: 1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3.
MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 109 for the part numbers of Polaris products. 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.
POLARIS PRODUCTS Description Part No. Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.
SUSPENSION TROUBLESHOOTING Problem Solution (perform only one change at a time) Rear suspension bot- • Verify sag dimension (see page 34). Adjust torsion spring toms too easily blocks or install optional torsion springs to achieve correct sag dimensions. • Increase shock compression damping (see page 37). Rear suspension rides too stiff • Check for binding suspension components and grease all pivot points. • Verify sag dimension (see page 34).
TROUBLESHOOTING Belt Wear/Burn Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during acceleration or load variations Drive clutch binding • Disassemble drive clutch to inspect shift weights for wear and free operation. SEE YOUR DEALER. • Clean and polish stationary shaft hub. Driven clutch malfunction • Replace ramp buttons and rollers. SEE YOUR DEALER.
Engine Troubleshooting Problem Noise in drive system Poor low RPM performance Probable Cause TROUBLESHOOTING Solution Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace if necessary. Drive chain loose or worn, sprocket teeth broken • Inspect and adjust or replace. Worn drive belt • Inspect and replace if necessary. Excessive belt/sheave clearance • SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause Solution Faulty ignition • Remove spark plug(s) and replace with new plug(s). If engine still fails to start, check for spark; if no spark SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is ON. Check tank level and fill up with correct fuel. • Ice in fuel line, filter, or pump. On the standard Polaris carburetor, the choke will not function with the throttle depressed.
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.
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 transferable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Conditions and Exclusions WARRANTY In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 125
MAINTENANCE LOG DATE 126 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 127
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . 39 Air Box Warning . . . . . . . . . . . . . . . 23 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches. . . . . . . . . . . . . . . . . . . . 15 Disabled Operators . . . . . . . . . . . . . . 13 Drive Belt Safety . . . . . . . . . . . . . . . . . . . . . 18 Adjustment . . . . . . . . . . . . . . . . 90 Condition . . . . . . . . . . . . . . . . . . 87 Deflection . . . . . . . .
INDEX I Ice and Snow Build-up . . . . . . . . . . . IFS Adjustment Options . . . . . . . . . . IFS Components . . . . . . . . . . . . . . . . Ignition Altitude Settings . . . . . . . . . Intake Filter. . . . . . . . . . . . . . . . . . . . Intake Silencer . . . . . . . . . . . . . . . . . P 16 29 29 62 76 19 Parking Brake Lever Lock . . . . . . . . 46 Passenger Warning . . . . . . . . . . . . . . 23 Periodic Maintenance Table . . . . 66-69 Polaris Products . . . . . . . . . . . . . . .
INDEX S T Storage, Daily . . . . . . . . . . . . . . . . 105 Storage, Extended . . . . . . . . . . 106-108 Survival Preparation . . . . . . . . . . . . 11 Suspension Adjustments, Front . . . . . . . 29-32 Adjustments, Rear . . . . . . . . 33-37 Inspections . . . . . . . . . . . . . . . 100 Lubrication, Front . . . . . . . . . . 70 Lubrication, Rear . . . . . . . . . . . 71 Performance Tips. . . . . . . . . . . 33 Troubleshooting. . . . . . . . . . . 110 Track Alignment . . . . . . . . . . . . . . . . .
