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 enthusiasts. Visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more. At Polaris we proudly produce an exciting line of utility and recreational products.
WELCOME Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you. We've provided this owner's manual to assist you and your children in learning about the safe operation and care of your new Polaris snowmobile. Please review the information in this manual with any child who may operate the snowmobile. Help your children learn to operate the snowmobile with safety as a top priority.
WELCOME Dear Children: Before you ride your new Polaris snowmobile, there are some important things that you need to know. Your parents and Polaris want you to enjoy riding your new snowmobile, and that's why you need to read and understand the information in your owner's manual. Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2006 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Important Notes for Owners and Drivers. . . . . . . . . . . . 6 Preservation of the Environment . . . . . . . . . . . . . . . . . . 7 Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . 9 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Youth Section . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Know Your Snowmobile . . . . . . . . . . . . . . . . . . . . . . .
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. You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage. NOTE: The illustrations and photos used in this manual are general representations. Your model may differ.
INTRODUCTION Preservation of the Environment Teach your child to drive their snowmobile with consideration for the protection and preservation of the environment. Noise One of the most publicized subjects with regard to snowmobiles is noise. The Society of Automotive Engineers (SAE), which is the standard-setting body for snowmobiles, has recommended that snowmobiles conform to prescribed sound levels. This Polaris snowmobile has been engineered to conform to these SAE standards.
INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protection of our environment, wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. It is very important that we encourage them as well as become actively involved ourselves.
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 The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY WARNING Failure to follow the warnings in this manual can result in severe injury or death. Read and understand the owner's manual and all warning decals before operating a Polaris snowmobile. Adults must thoroughly explain this information, including all safe operating procedures, to all operators of the snowmobile. All operators must be at least six (6) years old and must understand the consequences and risks if they choose to ignore or neglect this information.
SAFETY Maintenance Program This snowmobile is not a toy. The information in this manual is provided to aid you in its safe operation. For the safety of the operator, always make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, as well as an adult, check major and vital safety components before each use of the vehicle.
SAFETY Safety Decals Safety and warning decals have been placed on the vehicle for the operator's protection. Make sure the operator understands the information on all decals. If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. General Warning Decal WARNING • Read and understand warnings and the Owner’s Manual before operation.
YOUTH SECTION Know Your Snowmobile Before you have an adult start the engine for you for the first time, let's learn about the controls on your new snowmobile. Throttle Lever Brake Lever Engine Stop Switch Tether Strap/Switch Ignition Key & Switch Fuel Cap Choke Knob Recoil Starter Handle Hood Hold-Down Strap Engine Stop Switch When the engine is running, push this button down to stop the engine. Pull the stop switch up before trying to start the engine again.
Know Your Snowmobile YOUTH SECTION Gas Cap An adult will take the gas cap off to put gas in your snowmobile. Never take the gas cap off. Always make sure it's tightly closed. Always have an adult put gas in your snowmobile. Never try to do it yourself. Brake Lever Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop. Always take your thumb off the throttle lever when you squeeze the brake lever.
YOUTH SECTION Know Your Snowmobile Let's learn more about the parts of your snowmobile before we learn about riding.
Know Your Snowmobile YOUTH SECTION Hood The hood covers the moving and hot parts of the engine. Always make sure the hood is securely latched before you ride. Headlight The headlight is always on when the engine is running. It helps others see you when you're riding during daylight, but it's not meant to be strong enough to help you see in the dark. Drive your snowmobile only in the daylight. Windshield Always keep your windshield clean so you can see through it.
YOUTH SECTION Know Your Snowmobile STOP Let's review the 3 ways to stop your snowmobile: 1. Push the stop switch down. 2. Pull the tether strap off the switch. 3. Turn the key off.
Pre-Ride Check YOUTH SECTION You're almost ready to have an adult start your snowmobile. But first you must do a PRE-RIDE CHECK to make sure the snowmobile is safe to ride. Every time you want to ride your snowmobile, always have an adult help you check these things before you start the engine. n Throttle Lever Squeeze the throttle lever toward the handlebar and then let it go. The lever should go right back to where it was before you squeezed it.
YOUTH SECTION Pre-Ride Check n Gas Level Always have an adult put gas in your snowmobile. Never try to do it yourself. Have an adult check the gas level to see if your snowmobile needs more gas. Children should never open the gas cap or add gas. Always have an adult do this. Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 in this Owner's Manual. n Oil Level Have an adult check the engine oil level when the engine is cold.
Riding Rules YOUTH SECTION Now you're ready to learn about driving your Polaris snowmobile. This snowmobile is not a toy. There are some things you can do and there are some things you must never do. Rules are very important when you're driving a snowmobile. Adults have riding rules, too. The rules help keep us safe when we ride. You must be at least six (6) years old before you can ride this snowmobile. The adult with you is your teacher.
YOUTH SECTION Riding Rules Helmet Jacket Goggles Gloves Snowpants Boots " " " 22 Always wear the right kind of clothing when you ride your snowmobile. Always wear a helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your clothing fits properly. Tight clothing could keep you from moving easily. Baggy clothing could hang down and get caught in the track or another moving part. Never wear a long scarf.
YOUTH SECTION Riding Rules " " " " " Always sit down when you drive. Keep both hands on the handlebars. Keep both feet on the running boards. Never follow another snowmobile too closely. Always allow lots of space to stop your snowmobile. Ride your snowmobile only where you know it's safe to drive and where you have permission to drive. Always be a polite driver. Don’t drive through the flower garden or over small trees. Always attach the tether strap to your wrist and to the snowmobile before riding.
YOUTH SECTION Riding Rules Learn how to use your hands and arms as signals. Use these signals to let others know when you are getting ready to turn or stop your snowmobile. Read and understand your Owner's Manual.
Pre-Ride Check ADULT SECTION As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehicle without adult supervision. WARNING Serious injury or death could result if the vehicle is not inspected properly before operation. Teach all operators to perform the following Pre-Ride Check before each use of the snowmobile.
ADULT SECTION Pre-Ride Check n Read and Understand Your Owner's Manual Read and make sure the operators understand the Owner's Manual completely before allowing anyone to operate this snowmobile. It's also a good idea to review it periodically to reinforce the information. It's very important to familiarize all operators with the cautions and warnings pertaining to the machine as well as safe operating procedures.
ADULT SECTION Pre-Ride Check n Check the throttle safety switch Test the throttle safety switch system on a daily basis before the vehicle is used. With the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration. Apply a slight amount of throttle opening. A properly functioning switch must shut down the engine.
ADULT SECTION Pre-Ride Check n Inspect the track Driving for extended periods of time with marginal lubrication could severely damage the track. Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide marginal lubrication and are not recommended. Do not operate the snowmobile with a damaged track. WARNING Operating the snowmobile with a damaged track will increase the possibility of additional track damage and/or failure.
Operation Warnings ADULT SECTION n Do not carry passengers This snowmobile is designed for a single operator. n Do not operate with intake silencer removed CAUTION If the engine is operated with the intake silencer removed, damage to the engine may occur. Do not operate the engine with the intake silencer removed. n Stay clear of track WARNING During warm-up and operation, stand clear of the rotating track. Entanglement and serious injury or death may result.
ADULT SECTION Operation Warnings n Do not touch the engine after it's been running WARNING Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. n Disabled operators WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control, which could result in serious injury or death.
Operation Warnings ADULT SECTION n Check brake lever travel Depress the brake lever fully. Measure the clearance between the lever and brake block. Clearance should be no more than 3/4" (1.9 cm). Excessive travel indicates a need to adjust the brake cable. Refer to the mechanical brake adjustment information on page 56. n Secure the hood The hood of the snowmobile protects the operator from moving and hot parts as well as aiding in sound emission control and other functions.
ADULT SECTION Operation Warnings n Check surroundings Make sure the operation area is clear of obstacles and bystanders. Some sideways movement is possible when the snowmobile first begins to move, and debris may be thrown by the track. Teach the operator to check the operating area before riding. n Sit properly on the snowmobile Operating a snowmobile requires skill and balance for proper control. An improper position can reduce the child's ability to control the snowmobile.
Operation Warnings ADULT SECTION n Always wear clothing designed for snowmobiling Always make sure the operator is wearing an approved helmet and eye protection. Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts. If your child has long hair, be sure it is always tied up securely and tucked into the helmet or jacket. Helmet Wearing a helmet can prevent a severe head injury.
ADULT SECTION Operation Warnings n Stop engine before attempting adjustments WARNING The snowmobile engine compartment contains moving parts. Shields and guards have been provided for safety, but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft. For this reason never attempt adjustments with the engine running. Serious personal injuries can result.
Operation Warnings ADULT SECTION n Instruct all operators Teach all young drivers to always be alert and to pay attention to the driving area ahead. When teaching inexperienced operators to ride, set up a predetermined course. Establish boundaries and make sure all operators know and understand them. Make sure they know how to drive and control the snowmobile before you allow them to drive longer supervised distances. Teach them proper snowmobile courtesy.
ADULT SECTION Operation Warnings Driving Responsibly As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehicle without adult supervision. Drive-Away from Parked When the snowmobile has been parked for more than a few hours, especially overnight, the skis and track may freeze to the ground. Loosen the skis and track for the operator.
Operation Warnings ADULT SECTION Snow Conditions This snowmobile is designed to operate best on snow. Maneuverability is attained by the steering, skis, and the shifting of the driver's body weight. Maximum control will be attained by shifting body weight. Maneuverability will change for lighter operators. If the snowmobile becomes stuck in snow, stop the engine. Clear the snow away from the running board area and clear away or step down the snow in front of the snowmobile.
ADULT SECTION Operation Warnings Driving on Hills Traveling on hills is not recommended. A child may not be capable of maneuvering body weight as needed for operating on hills. If traveling on hills is unavoidable, teach your child to use extreme caution and obey the following proper operating procedures. WARNING Serious injury or death can result if the snowmobile rolls or slides downhill.
ADULT SECTION Operation Warnings Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.
ADULT SECTION Component Identification Flag Seat and Storage Handlebar Taillight Windshield Headlight Rear Bumper Hood Snow Flap Ski Rear Suspension Track Trailing Arm 40 Nosepan Front Bumper
Component Identification Throttle Lever ADULT SECTION Engine Stop Switch Tether Strap/Switch Ignition Key & Switch Fuel Cap Choke Knob Recoil Starter Handle Hood Hold-Down Strap Brake Lever 41
ADULT SECTION Break-In Period Engine Break-In The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts.
Operation ADULT SECTION Fuel When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M)/2 octane. Do not use E-85 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 smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
ADULT SECTION Operation Speed/Performance Regulation As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehicle without adult supervision. You can regulate the speed and acceleration of the snowmobile. CAUTION Hot engine components can cause serious burns to skin. Always perform the following procedures when the engine is cool.
ADULT SECTION Operation Starting the Engine Never start the engine before performing the Pre-Ride Check. See pages 19 and 25. 1. Turn the key to ON. 2. Pull the engine stop switch up to the RUN position. 3. Do not use the choke when starting a warm engine. If the engine is cold, pull the choke lever completely out to the FULL ON position. NOTE: Do not apply throttle while starting. 4. Grasp the starter handle and pull slowly until the recoil engages, then pull abruptly to start the engine.
ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the snowmobile in the event of an emergency. See pages 14 and 27 for more information about the engine stop switch and throttle safety switch.
Operation ADULT SECTION Pre-Ride Warm-Up Always warm up the engine, drive train and track before operating the snowmobile. Support the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. WARNING A loose track or flying debris could cause serious personal injury or death. Be sure the rear support is stable. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while performing this procedure.
ADULT SECTION 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.
ADULT SECTION 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 94. The recommended maintenance schedule for your snowmobile calls for a service and maintenance inspection at 50 hours, at 100 hours and at 150 hours.
ADULT SECTION Maintenance Periodic Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.
ADULT SECTION Maintenance Periodic Maintenance Chart ITEM SEE PAGE DAILY WEEKLY OR BEFORE EXTENDED PERIOD OF OPERATION 50 HRS 100 HRS 150 HRS Check track alignment 65 X Check track condition 67 X Check drive chain tension 59 X Check and tighten any loose suspension mounting bolts 72 X Tighten ski saddle and spindle bolts if loose -- X Check front and rear limiter strap condition, tighten loose bolts -- X Check slider thickness, replace when worn (see dealer) 68 X Tighten rear id
ADULT SECTION Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section beginning on page 80 for recommended spark plug type and gap. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use the spark plugs recommended for your snowmobile.
Maintenance ADULT SECTION Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. Wet Fouled Plug The wet fouled insulator tip is black.
ADULT SECTION Maintenance Fuel Valve/Fuel Lines Inspect the fuel valve and the fuel lines regularly. Carefully check the system's fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds can occur. Replace any worn or damaged components. Exhaust System At approximately 50 hours, check the exhaust system for wear or damage. To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage.
ADULT SECTION Maintenance Carburetor Proper carburetor adjustment is critical, since a mixture too lean (too much air, too little fuel) will result in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failure. A lean mixture can be the result of fuel line restrictions, foreign matter in the carburetor, etc.
ADULT SECTION Maintenance Brake Lever Travel 3/4" (19 mm) Firmly depress the brake lever. Measure the clearance between the lever and brake block. If clearance is more than 3/4" (19 mm), adjust the brake cable as outlined below. Brake Cable Adjustment If proper adjustment cannot be achieved using the following methods, check the brake band. If the brake band has excessive wear, see your Polaris dealer for installation of a new band.
Maintenance ADULT SECTION Brake Cable Adjustment 4. Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and that all parts are mounted securely. Tighten hardware as required. 5. Tighten the adjuster jam nut and slide the rubber protectors onto the adjuster. 6.
ADULT SECTION Maintenance Throttle Cable Lubrication With the engine off, lubricate the throttle cable occasionally. Turn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate the choke intermittently before turning the engine off. This draws moisture out of the choke plunger area and reduces the possibility of the choke becoming frozen.
Maintenance ADULT SECTION Chain Tensioner Inspect the chain. Proper deflection is one inch (25 mm). Adjust the chain if deflection is incorrect. 1. Loosen the nut on the chain tensioner. 2. Raise the tensioner until the correct deflection is attained. 3. Tighten the nut to 15-18 ft. lbs. (20-24 Nm). NOTE: When the chain has stretched to within 1/8" (3 mm) of the muffler mount bracket on the chassis, replace the chain.
ADULT SECTION Maintenance Driveline Lubrication NOTE: Driveline noise is normal for this vehicle. To ensure long life of the snowmobile's driveline, lubricate as follows: • Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. • Lubricate Point B every 10 hours of operation with aerosol chain lube or SAE 30 oil.
ADULT SECTION Maintenance Engine Oil Oil Recommendations Polaris recommends the use of Polaris Premium 4 All Season Synthetic Oil or any class SE, SF (API classification) or higher grade oil. If multigrade oil is used, oil consumption will increase when the ambient temperature is high. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Perform the break-in oil change after 20 hours of operation.
ADULT SECTION Maintenance Engine Oil Oil Change 1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. 2. Place a drain pan under the drain plug. NOTE: The drain plug is located under the bulkhead and in front of the engine. 3. Remove the drain plug. 4. Remove the dipstick and wipe it dry with a clean shop towel. Drain Plug Dipstick NOTE: The oil will drain faster with the dipstick removed. 5. Allow the oil to drain completely. 6.
Maintenance ADULT SECTION Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. 1. Operate the snowAdjusting Screw mobile to warm up the track. 2. Stop the engine. 3. Support the rear of the snowmobile slightly off the ground with an appropriate snowIdler mobile support. Shaft 4. Hang a 10-pound Bolt (4.5 kg) weight 8 8" (20 cm) 10 lbs. inches (20 cm) from (4.5 kg) the center of the rear idler wheel. 5.
ADULT SECTION Maintenance Track Tension Adjustment 1. Loosen the rear idler shaft bolt. 2. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track. 3. Repeat the measurement on the other side of the track. NOTE: Check tension more frequently when the machine is new. WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.
Maintenance ADULT SECTION Track Alignment Check track alignment at the intervals outlined in the periodic maintenance chart beginning on page 50. Make sure the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury. Make sure the track contains no objects that could be thrown out while the track is rotating.
ADULT SECTION Maintenance Track Warm Up After storing your snowmobile outside overnight, warm up the track before driving the snowmobile. This reduces drive clutch wear. 1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. WARNING Never hold the snowmobile up or stand behind it while rotating the track. A loose track or flying debris could cause serious personal injury or death. 2. Start the engine. 3.
ADULT SECTION Maintenance Track Inspection Check track condition at the intervals outlined in the periodic maintenance chart beginning on page 50. WARNING Inspecting the track while the engine is running can result in serious personal injury if the track should being to move. Never inspect the track with the engine running. Never hold the snowmobile up or stand behind it while rotating the track. A loose track or flying debris could cause serious personal injury or death. 1.
ADULT SECTION Maintenance Slider Replacement 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.
ADULT SECTION Maintenance Steering Inspection Each week, or before a long ride, check all steering system fasteners. Tighten any loose fasteners. The stars in the illustration below indicate fastener locations. Steering Adjustment 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.
ADULT SECTION Maintenance Handlebar Adjustment 1. Slide the handlebar pad upward to access the adjuster bolts. If additional room is required, unzip one Lower of the handlebar pad zippers Nut and roll the pad to the side. 2. Remove the upper flange nut and carriage bolt. 3. Loosen the lower flange nut only enough so the bracket Upper Bolt can move freely. 4. Position the handlebar to the desired height. 5. Reinstall the upper carriage bolt and flange nut. 6. Torque both flange nuts to 15-17 ft. lbs.
ADULT SECTION Maintenance Ski Skags The skag is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads Skag and other bare terrain. Check skags weekly to maintain positive steering characteristics. Replace skags when they are worn to half their original diameter. NOTE: See the dealer track studding and skag chart for recommended skags.
ADULT SECTION Maintenance Lubrication Recommendations Suspension To maintain rider comfort and to retard wear of the pivot shafts, lubricate the suspension pivot shafts with Polaris Premium All Season Grease several times during the season and again before summer storage each year. Lack of lubrication will result in reduced performance and a less comfortable riding experience. NOTE: The stars in the following illustration indicate lubrication points.
Maintenance ADULT SECTION Lubrication Recommendations Inspect and lubricate all greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Controls and Linkage Lubricate all bushings, spindle shafts, and tie rod ends with a light coat of oil or grease. Lubricate throttle and brake controls and cables with Polaris Premium All Season Grease. Force a small amount of lubricant down the cable.
ADULT SECTION Maintenance Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1.
Maintenance ADULT SECTION 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. Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. See page 76. 2. Support the front end of the machine so the engine is level or tilted slightly rearward. 3. Turn the fuel valve off. 4. Remove the spark plug. 5. Pour 5cc of Premium 4 Synthetic 0W40 engine oil into the cylinder. 6.
ADULT SECTION Maintenance Storage Stabilize the Fuel Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage. See page 82 for the part numbers of Polaris products. 1. Fill the fuel tank with fresh fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
Maintenance ADULT SECTION Storage Track and Suspension Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. This will allow the track to hang freely. Elevate the front end of the machine and place blocks securely under it to remove tension from the shocks and springs. This will minimize fatigue on the front shocks and springs. Storage Area Your snowmobile should be stored in a dry garage or shed, out of direct sunlight.
ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken: 1. Turn the fuel valve off. 2. Be sure the fuel cap is installed correctly. 3. Always tie the snowmobile to the transporting unit securely using suitable straps. Fall Tune-Up To obtain maximum performance from your snowmobile, we encourage you to arrange for a fall service tune-up with your Polaris dealer.
TROUBLESHOOTING Engine Turns Over, Fails to Start Contact your Polaris dealer for service if you're unable to identify solutions using the following chart.
SPECIFICATIONS Capacities and Dimensions Body Style Rider/Weight Capacity Dry Weight Fuel Tank Capacity Engine Oil Capacity Height Length Width Track Length Track Width Brake Type Ski Center Distance Clutch Type Drive Chain Length Mini Indy 1/150 lbs. (68 kg) maximum 147.5 lbs. (67 kg) .5 gal. (1.9 l) 20 oz. (.6 l) 31 in. (78.7 cm) 75 in. (190.5 cm) 34 in. (86.4 cm) 69 in. (175.3 cm) 10 in. (25.4 cm) Mechanical 30 in. (76.
SPECIFICATIONS Carburetor Jetting AMBIENT TEMPERATURE ALTITUDE Meters (Feet) Below -30° to -10°F -15° to +5°F 0° to +20°F +15° to +35°F +30° to +50°F +45° to +65°F Above (-9° to +2°C) (-1° to +10°C) (+7° to +18°C) +60°F -25°F (-34° to -23°C) (-26°C to -15°C) (-18° to -7°C) (-31°C) (+16°C) NOTE: Main jet is the first number in each cell; Pilot jet is the second number (in italics) 0-600 (0-2000) 72.5 55 72.5 55 70 50 70 50 70 50 67.5 50 67.5 45 67.
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Premium Front Gearcase Fluid (8 oz.) 2871654 Premium Demand Drive Hub Fluid (8 oz.) 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.
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.
WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
WARRANTY Polaris Second Year Engine Service Contract Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion. Coverage is automatic with no additional paperwork required. The free Second Year Engine Service Contract is subject to a $50 deductible per visit. Regular, documented service maintenance visits are required to validate this warranty.
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
WARRANTY Exported Vehicles How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine meets current U.S. Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068.
WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use.
MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.
MAINTENANCE LOG DATE HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 95
INDEX A H Air Pollution . . . . . . . . . . . . . . . . . . . 7 Handlebar Adjustment. . . . . . . . . . . . 70 Hood Hold-Down Strap. . . . . . . . . . . 15 B Bearings . . . . . . . . . . . . . . . . . . . . . . 73 Brake Cable Adjustment . . . . . . . 56-57 Brake Lever . . . . . . . . . . . . . . . . . . . 15 Brake Lever Travel . . . . . . . . . . . . . 56 Break-In Period . . . . . . . . . . . . . . . . 42 C D 46 36 60 38 36 E F 78 43 54 54 G Gas Cap . . . . . . . . . . . . . . . . . . . . . .
INDEX S T Safety Decals . . . . . . . . . . . . . . . . . . 13 Safety Symbols . . . . . . . . . . . . . . . . . 10 Signal Words. . . . . . . . . . . . . . . . . . . 10 Skag Replacement. . . . . . . . . . . . . . . 71 Ski Skags. . . . . . . . . . . . . . . . . . . . . . 71 Slider Replacement . . . . . . . . . . . . . . 68 Snow and Ice Build-Up. . . . . . . . . . . 36 Snow Conditions. . . . . . . . . . . . . . . . 37 Spark Plug Condition . . . . . . . . . . . . 52 Spark Plugs . . . . . . . . . . . . . . . .
