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 2008 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 This section describes safe vehicle operation and identifies warning decals and their locations. Features and Controls . . . . . . . . . . . . . . . . . . .
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.
Operator Safety 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 61 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.
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.
Operator Safety SAFETY Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22. WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
SAFETY Operator Safety 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 Excessive Speed WARNING High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They’ve been established for your protection. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels.
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 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, check for ice and snow build-up that may be obstructing the steering linkage.
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.
SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine’s compression to help slow the machine and keep it from rolling freely downhill. WARNING When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure.
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 WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.
Operator Safety SAFETY Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.
Safety Decals and Locations SAFETY Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.
SAFETY Safety Decals and Locations 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 Widetrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument housing.
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 GeneralRepresentation 5 4 6 7 3 8 9 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. Refer to your Owner’s Manual Supplement. NOTE: 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 7 4 3 5 6 8 9 2 1 10 11 12 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 14 13 Hood Headlight Windshield Handlebar Operator Seat Passenger Hand Hold Strap Cargo Rack Taillights Snow Flap Track Suspension Trailing Arm Nosepan Front Bumper (do not use for pulling or dragging the snowmobile) Skis Cargo Rack Always secure cargo before operating. Do not exceed the rack weight limit specified on the cargo rack decal.
Backrest FEATURES AND CONTROLS The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest forward for operator use or rearward for passenger use. 3.
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 Always verify ski alignment before making adjustments to the IFS. See page 94 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming.
THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-toground pressure. 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. Special tools are required to adjust front springs.
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 WideTrak Rear Suspension Adjustments Rear Spring Settings Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs. 2. Slowly lower the machine and measure the distance between the ground and the running board. 3. Without letting the suspension settle, the rider should carefully mount the snowmobile. 4. Measure the distance between the ground and the same spot on the running board.
Handlebar Adjustments THE PERFECT FIT Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar by removing nuts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear nuts). Bar Bolts Nuts NOTE: If necessary, pry the blocks apart with a screwdriver. 3. Adjust the handlebar to the Nuts desired angle.
THE PERFECT FIT Traction Products nCarbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Inspect skags frequently. Worn skags may reduce steering and braking control on hard-packed snow and ice. Replace worn skags to maintain proper balance and vehicle control. WARNING Loss of control can result in serious personal injury or death.
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.
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.
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 Hydraulic 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 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. See pages 78-79 or see your dealer for service. 1/2 inch (1.
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 2 3 4 1 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4.
PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated. n Track WARNING Always inspect the track for damage before using the vehicle.
PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmobile.
PRE-RIDE INSPECTIONS Start the Engine and Check 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 50. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately. Oil Recommendations This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems.
OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
OPERATION Fuel Reserve Capacity (Mechanical Gauge) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol.
OPERATION n Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 47 for oil recommendations. When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank. If oil is not visible, continued operation may cause serious engine damage. Never mix brands of oil.
OPERATION n Oil Low Oil Level Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 47 for oil recommendations. The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts. Carburetion Proper carburetor adjustment is critical.
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 74 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.
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 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 54 for more information about the engine stop switch and throttle safety switch.
OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. If the recoil starter system fails, an emergency start strap is provided in the kit. Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.
OPERATION 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. 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.
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, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
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 120. 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 Suspension and Steering 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. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 105 for the part numbers of Polaris products. The illustration shows the lubrication points of suspension and steering components. Grease the left and right spindles.
Lubrication MAINTENANCE Rear Suspension WideTrak Rear Suspension + + + + + 67
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.
MAINTENANCE Lubrication n Gearcase Oil Level (WideTrak) Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 65. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. 2 1 To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (1). See your Polaris dealer for the recommended oil for your machine. Do not overfill.
MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. NOTE: Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color.
MAINTENANCE Intake Filter The intake foam filter 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.
MAINTENANCE Carburetor 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. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 40. 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. 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 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 NOTE: 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 alcoholmoistened towel. Headlight Bulb Replacement 1. Pinch the ends of the spring (1) 3 together and lift until it releases from the spring retainer. 2. Lift the spring carefully around 2 the wire harness (2) and flip it to the outside of the 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. WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer.
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 107. 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. 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. Firmly grasp the belt midway between the clutches and pull upward and rearward to remove. See illustration.
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. 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. 1 2 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). 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. .010-.030 in. (.25-.75 mm) Adjust if necessary, and lock the jam nut. 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 76.
MAINTENANCE Track Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 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 (+).
MAINTENANCE Track 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.
MAINTENANCE Track Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 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 machine is new. Slack Measurement Locknut Adjusting Screw Track Idler Shaft Bolt 16 in. (40 cm) 10 lbs. (4.54 kg) 9.
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.
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. Check skags weekly to maintain positive steering characteristics.
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.
MAINTENANCE Battery 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 Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.
MAINTENANCE Battery Battery Installation 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. NOTE: The vent tube must be free of obstructions and securely installed. Route the vent tube properly to prevent kinks and to allow for proper drainage.
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. NOTE: 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 105 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.) 2874438 VES II Synthetic 2-Cycle Engine Oil (qt.
SUSPENSION TROUBLESHOOTING Problem Solution (perform only one change at a time) Rear suspension bot- • Verify sag dimension (see page 91). Adjust torsion spring toms too easily blocks or install optional torsion springs to achieve correct sag dimensions. Rear suspension rides too stiff • Check for binding suspension components and grease all pivot points. • Verify sag dimension (see page 91). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions.
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 NOTE: 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. NOTE: A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. NOTE: B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2.
Limited Warranty WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty. The warranty begins on the date of purchase. This warranty is transferable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Conditions and Exclusions WARRANTY In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissionscertified snowmobile engine is designed, built and equipped so it conforms with U.S. Environmental Protection Agency regulations applicable to snowmobile emissions.
WARRANTY Snowmobile Engine Emissions Limited Warranty 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. This limited warranty also does not cover any engine that has been structurally altered, or when the snowmobile has been used in racing competition.
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 121
MAINTENANCE LOG DATE 122 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 123
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . 37 Air Box Warning . . . . . . . . . . . . . . . 23 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Apparel . . . . . . . . . . . . . . . . . . . . . . 11 Avalanches. . . . . . . . . . . . . . . . . . . . 15 Disabled Operators . . . . . . . . . . . . . . 12 Drive Belt . . . . . . . . . . . . . . . . . . . . . 18 Adjustment . . . . . . . . . . . . . . . . 86 Condition . . . . . . . . . . . . . . . . . . 83 Deflection . . . . . . . . . . . .
INDEX L Lever, Shift (Mechanical Reverse) . . 57 Lights . . . . . . . . . . . . . . . . . . . . . 80-81 Headlight Adjustment . . . . . . . . 80 Lubrication Choke and Cable . . . . . . . . . . . . 68 Driveshaft Bearing . . . . . . . . . . 68 Jackshaft Bearing . . . . . . . . . . . 68 Rear Suspension . . . . . . . . . . . . 67 Throttle Cable . . . . . . . . . . . . . . 68 M Maintenance Interval Table . . . . . . . 62 Maintenance Program . . . . . . . . . . . . 61 Maneuverability . . . . . . . . . . . . . . .
INDEX T V Throttle Lever . . . . . . . . . . . . . . 39, 55 Throttle Safety Switch . . . . . . . . 39, 54 Tool Kit . . . . . . . . . . . . . . . . . . . . . . 87 Torque Stop . . . . . . . . . . . . . . . . . . . 87 Towing. . . . . . . . . . . . . . . . . . . . . . . 58 Track Alignment . . . . . . . . . . . . . . . . 92 Damage . . . . . . . . . . . . . . . . . . 42 Inspection. . . . . . . . . . . . . . . . . 88 Lubrication. . . . . . . . . . . . . . . . 89 Tension . . . . . . . . . . . . .
