Polaris Offroad Vehicle 120 Youth User Manual

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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.  
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WELCOME  
Thank you for purchasing a Polaris vehicle, and welcome to our world-  
wide family of Polaris enthusiasts. Visit us online at www.polarisindus-  
tries.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.  
• Snowmobiles  
• All-terrain vehicles (ATVs)  
RANGER utility vehicles  
• Victory motorcycles  
We believe Polaris sets a standard of excellence for all utility and recre-  
ational vehicles manufactured in the world today. Many years of experi-  
ence have gone into the engineering, design, and development of your  
Polaris vehicle, making it the finest machine we've ever produced.  
We also take great pride in our complete line of apparel, parts and acces-  
sories, available through our online store at www.purepolaris.com. Have  
your accessories and clothing delivered right to your door!  
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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.  
Help them also learn to show respect for our environment and for the  
rights of others while operating the snowmobile. Since the operator will  
be a newcomer to the exciting winter sport of snowmobiling, please be  
sure he/she understands this information before riding the snowmobile.  
Never allow a child to operate the snowmobile without adult supervi-  
sion.  
This Owner's Manual contains instructions for minor maintenance, but  
major repairs are covered in the Polaris Service Manual and should be  
performed by a Factory Certified MSD (Master Service Dealer) Techni-  
cian. Be sure to return to your dealership for all of your service needs  
during, and after, the warranty period.  
The preventive maintenance program outlined in this manual is  
designed to ensure that all critical components on your child's snowmo-  
bile are thoroughly inspected at various intervals. If you have any ques-  
tions about the snowmobile, contact a Polaris dealer for assistance. See  
page 82 for the part numbers of Polaris products.  
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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.  
As the driver of the snowmobile, you must learn how to keep yourself  
and those around you safe while you're riding. So read your manual, and  
then enjoy riding your new Polaris snowmobile!  
3
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-  
tries Inc.  
Copyright 2007 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 discrep-  
ancies may result between the actual vehicle and the information presented in this publi-  
cation. Depictions and/or procedures in this publication are intended for reference use  
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse  
of the depictions and/or procedures contained within, whether whole or in part, is  
expressly prohibited.  
Printed in U.S.A.  
2008 120 Snowmobile Owner's Manual  
P/N 9921100  
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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 . . . . . . . . . . . . . . . . . . . . . . . 14  
Pre-Ride Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Riding Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
Adult Section . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Pre-Ride Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Operation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Component Identification. . . . . . . . . . . . . . . . . . . . . . . 40  
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
Emission Control Information . . . . . . . . . . . . . . . . . . . 48  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 79  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 80  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 82  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 94  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96  
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INTRODUCTION  
Important Notes for Owners and Drivers  
After reading this manual, store it in the snowmobile for convenient ref-  
erence. 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 represen-  
tations. Your model may differ.  
IMPORTANT  
Parents should sit down with their children and read the Youth Section with  
them before allowing them to use this snowmobile. Parents must also read the  
Adult Section before allowing their children to ride this snowmobile.  
PARENTS: Do not allow anyone under the age of six (6) to operate this  
machine. Review the information in this manual with any child who  
may be operating the snowmobile. It is up to you to teach any operator  
the proper and safe way to ride a snowmobile. You must set boundaries  
and adhere to them, keeping the operator's safety foremost in your mind.  
Never allow a child to operate this machine without adult supervision.  
These units are not designed for adult use. Serious damage to the vehicle  
may occur if the maximum rider weight capacity is exceeded. Never  
exceed the maximum rider weight capacity. See page 80.  
CHILDREN: Before you ride your new Polaris snowmobile, there are  
some important things that you need to know. Your safety and the safety  
of others is the most important thing to think about at all times. As the  
driver of the snowmobile, you must learn how to keep yourself and  
those around you safe while you're riding.  
Pay attention when you see this symbol:  
This is the safety alert symbol. When you see this symbol on your  
snowmobile or in this manual it means PAY ATTENTION because you  
could die or be seriously hurt if you don't follow the instructions.  
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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 stan-  
dard-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.  
In order to be meaningful, all regulations require the cooperation of the  
snowmobile owner. Muffling systems, designed to reduce noise levels,  
should not be altered or removed. Snowmobile drivers must be aware  
that they have a public responsibility to operate their snowmobiles with  
concern for others. As a snowmobile operator you may not realize the  
sound of your snowmobile may annoy non-snowmobilers. We are  
attempting to do our part through the manufacture of quieter machines,  
and we also ask your help in the effort to further reduce the impact of  
noise.  
Air Pollution  
As a part of Polaris' plan for the snowmobile's compatibility within the  
environment, our engineers are investigating ways to reduce emission  
levels of engines. We expect our efforts to lead to the reduction of  
potential air pollution.  
The four-stroke engine used in this snowmobile produces less exhaust  
emissions and reduces noise, as well.  
In addition to technological research, we also suggest that governmental  
agencies, manufacturers, distributors, dealers, ecologists, and other  
interested parties work together to develop data on environmental top-  
ics. We will continue to participate in this type of study so that someday  
we may find the answers to these difficult issues.  
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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 protec-  
tion 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. Protect and preserve your right to ride by joining  
your local trail riding clubs. Teach your child the following:  
Respect your snowmobile;  
respect your environment;  
and you will earn  
the respect of everyone.  
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INTRODUCTION  
Vehicle Identification Numbers  
Record your snowmobile's identification numbers in the spaces pro-  
vided.  
Tunnel VIN  
Vehicle Model Number: ____________________________________________________  
Tunnel VIN: _____________________________________________________________  
(lower right side of the tunnel)  
Engine Serial Number: ____________________________________________________  
(right front side of engine crankcase)  
9
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SAFETY  
The following signal words and symbols appear throughout this manual  
and on your vehicle. Your safety is involved when these words and sym-  
bols 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.  
CAUTION  
The safety alert caution indicates a potential hazard that may result in minor  
injury or damage to the vehicle.  
CAUTION  
A caution indicates a situation that may result in damage to the vehicle.  
NOTE  
A note will alert you to important information or instructions.  
10  
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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 under-  
stand the consequences and risks if they choose to ignore or neglect this  
information.  
Equipment Modifications  
All Polaris snowmobiles have been designed and tested to provide safe  
operation when used as directed. Failure of critical machine components  
may result from operation with any modification; especially those that  
increase speed or power. There is a significant possibility of loss of con-  
trol at higher speeds.  
We are concerned for the safety of our customers and for the general  
public. Any modifications to the original equipment of the vehicle cre-  
ate a substantial safety hazard and increase the risk of bodily injury.  
Therefore, we strongly recommend that consumers do not install on a  
Polaris snowmobile any equipment that may increase the speed or  
power of the vehicle, or make any other modifications to the vehicle for  
these purposes.  
The warranty on your Polaris snowmobile is terminated if any equip-  
ment has been added to the vehicle, or if any modifications have been  
made to the vehicle, that increase its speed or power.  
11  
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SAFETY  
Maintenance Program  
This snowmobile is not a toy. The information in this manual is pro-  
vided 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 com-  
ponents before each use of the vehicle.  
We also recommend that you strictly follow the maintenance schedule  
outlined in this manual to ensure that all critical components on the  
snowmobile are thoroughly inspected by your dealer at various mileage  
intervals.  
12  
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SAFETY  
Safety Decals  
Safety and warning decals have been placed on the vehicle for the oper-  
ator'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.  
Severe injury or death can result from  
not heeding the warnings.  
General  
Warning  
Decal  
• This vehicle is intended for daylight use  
in restricted off-road areas clear of  
obstacles, primarily on snow and not  
on frozen bodies of water, by a child of  
not less than 6 years of age who is in  
the presence of, and in active supervi-  
sion of an adult. Use of this vehicle on  
public trails, streets, roads, and high-  
ways can be hazardous and is prohib-  
ited by law in most cases.  
• Do not start or operate this vehicle without guards and shields in position, or  
with hood not latched in place.  
• This vehicle is intended for one operator only, no passenger. Passengers,  
cargo, or towed objects can cause loss of control.  
• Verify proper operation of all controls before starting the engine.  
• When operating this vehicle, the operator shall wear suitable protective cloth-  
ing including an approved safety helmet and shield or goggles.  
• Securely attach the safety lanyard to the child’s body before starting the  
engine.  
• This vehicle can be operated between 0 and 8 mph (13 km/h). However, it is  
recommended that the adult supervising the child regulate the maximum  
speed to match the experience and ability of the child. Instructions for regulat-  
ing maximum speed are provided in the Owner’s Manual.  
• The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in  
case of emergency and is located on the top of the throttle control assembly.  
Depress the switch to stop the engine. Routinely check this switch for proper  
function with the engine idling.  
• If Owner’s Manual is missing, contact a Polaris Dealer for a replacement.  
13  
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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.  
Brake Lever  
Engine Stop Switch  
Throttle Lever  
Choke  
Knob  
Gas  
Cap  
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.  
Throttle Lever  
The throttle lever makes your snowmobile go forward when you press it  
with your thumb. Before you drive your snowmobile, always make sure  
the throttle lever does not stick. Read more about it on page 19.  
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.  
14  
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YOUTH SECTION  
Know Your Snowmobile  
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.  
Recoil Starter Handle  
Pull the recoil starter handle to start your snowmobile. An adult will  
help you start it the first time.  
Choke Knob  
You may need to use the choke to help start your snowmobile if the  
engine is cold. Read more about it on page 45.  
Hood Hold-Down Strap  
Two straps hold down the hood of your snowmobile. Always make sure  
both straps are latched before you start the engine.  
Tether Strap/Switch  
Attach to Loop or Wrist  
Always attach the tether  
strap to your body and to  
the switch on your snow-  
mobile every time you  
drive. If you fall off your  
snowmobile, the tether  
strap will pull away from  
the switch and the engine  
will stop.  
When you attach the strap  
to your body, you can clip  
it to a loop on your cloth-  
ing, or you can wrap the  
strap around your right  
wrist and attach the clip to  
the strap.  
Attach to  
Switch  
Never ride without the tether strap attached to your body and to your  
snowmobile. Be careful not to let the cord get tangled around the han-  
dlebars or any part of your body.  
15  
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YOUTH SECTION  
Know Your Snowmobile  
Let's learn more about the parts of your snowmobile before we learn  
about riding.  
Seat and  
Storage  
Handlebar  
Windshield  
Headlight  
Hood  
Taillight  
Snow  
Flap  
Track  
Ski  
16  
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YOUTH SECTION  
Know Your Snowmobile  
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.  
Handlebar  
The handlebar is connected to the skis. When you turn the handlebar, the  
skis turn in the same direction.  
Seat and Storage  
When the engine is stopped, you can take the seat cushion off and put  
things under the seat in the special compartment.  
Taillight  
The taillight is always on when the engine is running. It will help others  
see you when you're riding.  
Snow Flap  
The snow flap keeps snow, ice or other things from flying out behind  
your snowmobile.  
Track  
When you squeeze the throttle lever, the track turns and makes the  
snowmobile move forward.  
Never get close to a moving track. Never wear clothing that could get  
caught in a moving track, like a long scarf or baggy clothing. Tie up  
long hair.  
Skis  
The skis help you steer your snowmobile. When you turn the handlebar,  
the skis turn in the same direction.  
17  
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YOUTH SECTION  
Know Your Snowmobile  
STOP  
Let's review the 2 ways to stop your snowmobile:  
Push the stop  
switch down  
Pull the strap off  
the tether switch  
18  
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YOUTH SECTION  
Pre-Ride Check  
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. If it  
goes back slowly or stays close to the handlebar, you have a sticky throt-  
tle. This means that something is wrong or broken.  
Don't start the snowmobile until an adult fixes the sticky lever. You  
could get hurt if you ride with a sticky throttle.  
n Brake Lever  
Squeeze the brake lever toward the handlebar and then let it go. The  
lever should go right back to where it was before you squeezed it. If it  
goes back slowly or stays close to the handlebar, you have a sticky brake  
lever. This means that something is wrong or broken.  
Don't start the snowmobile until an adult fixes the sticky lever. You  
could get hurt if you ride with sticky brakes.  
n Seat Latches  
Check the seat latches. Make sure they are latched tightly.  
n Hood Hold-Down Straps  
Check the hood hold-down straps. Make sure they are latched tightly.  
n Track and Skis  
Never check the track or skis when the engine is running. You could  
get hurt if the snowmobile moves unexpectedly. Never stand behind or  
in front of any snowmobile when the engine is running.  
Make sure the engine is off, then stand behind the snowmobile and lift  
up the rear end. This will free the track if it is frozen to the ground.  
Turn the handlebars all the way to the left and to the right. This will turn  
the skis to make sure they aren't frozen to the ground.  
If any of this is hard to do, have an adult help you.  
19  
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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. The  
engine is very hot after it has been running. It could burn your skin.  
Children should never check the oil. Always have an adult do this.  
n 2 Ways to STOP  
Always check to make sure that BOTH WAYS TO STOP are working  
the way they should. Do you remember what they are? Follow these  
steps:  
1. Start the engine. Push the stop switch down. The engine should  
stop.  
2. Start the engine. Pull the tether strap off the switch. The engine  
should stop.  
If the engine does not stop when you do these checks, do not ride the  
snowmobile until an adult fixes it.  
20  
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YOUTH SECTION  
Riding Rules  
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 snowmo-  
bile. The adult with you is your teacher. Always pay attention to what  
your teacher says so you can learn how to always drive safely.  
Let's learn how to ride!  
Always follow the safe riding rules found on the next pages. You or  
others around you could be seriously hurt or killed if you don't follow  
the safe riding rules.  
" Your snowmobile is made for only one rider. Never carry a passenger.  
A passenger will make the snowmobile harder to drive. You may lose  
control and hurt yourself and your passenger.  
" Never pull anything behind your snowmobile.  
" Make sure you know where you're going to drive before you start the  
engine. Make sure the area is safe all around your snowmobile.  
" Never ride alone. An adult should always be watching you in case  
you need help. Always drive where an adult can see you.  
" Never ride on public trails.  
" When you're a beginner, always stay on level ground.  
" Don't ride your snowmobile on roads or over railroad tracks. Your  
snowmobile makes noise that will keep you from hearing cars, trucks  
or trains that may be coming toward you.  
" Stay away from fences. Make sure you know where all the fences are  
before you ride. If you drive into a fence, you could get hurt.  
" Don't ride at night. The headlight on your snowmobile is there only so  
others can see you driving during the day.  
21  
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YOUTH SECTION  
Riding Rules  
Helmet  
Goggles  
Gloves  
Jacket  
Snowpants  
Boots  
" Always wear the right kind of clothing when you ride your snowmo-  
bile. 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. Wear warm snowmobile boots and gloves,  
and make sure your boot laces are tied. If you have long hair, tie it up  
or put it inside your helmet or jacket.  
" Learn if there are lakes, rivers, ponds and ditches in your driving area.  
Stay away from them. Never ride on frozen water. Your snowmobile  
could fall through the ice into the water and you could drown or  
freeze to death.  
" Always be alert and pay attention to where you're driving. Always  
watch out for objects or people in your driving area and stay a safe  
distance away from them.  
22  
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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 body and to the switch on your  
snowmobile every time you drive.  
Keep both hands on  
the handlebars  
Sit down  
Keep both feet on  
the running boards  
Attach tether  
strap to loop  
or right wrist  
Attach tether strap to the  
switch on your snowmobile  
23  
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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 snow-  
mobile. Read and understand your Owner's Manual.  
Left Turn  
Right Turn  
Stop  
24  
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ADULT SECTION  
Pre-Ride Check  
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 vehi-  
cle 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.  
n Check the throttle for proper operation. See page 26.  
n Check the brake for proper operation. See page 26.  
n Check the steering system for proper operation. See page 26.  
n Check the throttle safety switch for proper operation. See page 27.  
n Start the engine and push the stop switch down to test for proper  
operation.The engine should stop immediately.  
n Start the engine and disconnect the tether switch to test for proper  
operation. The engine should stop immediately.  
n Inspect the track. See page 28.  
n Make sure the seat is securely attached.  
n Make sure the hood is latched.  
n Make sure the track and skis are not frozen to the ground.  
n Check the gas and oil levels for the rider. Add more if necessary.  
n Make sure the headlight and taillight are working properly.  
These checks should become automatic for the child before each ride.  
As the adult teacher, you must instill in all riders the importance of per-  
forming this Pre-Ride Check before they operate the snowmobile.  
25  
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ADULT SECTION  
Pre-Ride Check  
n Read and Understand Your Owner's Manual  
Read and make sure the operators understand the Owner's Manual com-  
pletely 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. We've  
attempted to provide you with as much information as possible to alert  
you to the safety requirements of snowmobiling.  
WARNING  
The throttle and brake are the primary controls of the snowmobile. If either  
should malfunction, the operator could lose control, which could lead to seri-  
ous injury or death. Always check the throttle and brake levers for proper  
operation before operating the vehicle.  
n Check the throttle for proper operation  
When checking the throttle, make sure the throttle lever compresses  
evenly and smoothly. When the lever is released, it should immediately  
return to the idle position without binding or hesitation. If the throttle  
does not function smoothly, do not start the engine. Have the throttle  
serviced before operating the snowmobile.  
n Check the brake for proper operation  
Squeeze the brake lever toward the handlebar. When the lever is  
released, it should return to it’s original position smoothly. If the lever  
hesitates or seems sticky, do not start the engine. Have the brakes ser-  
viced before operating the snowmobile. See page 31 for brake lever  
travel specifications.  
n Check for proper operation of the steering system  
Check for proper operation of the steering system. Manually turn the  
skis completely to the right and to the left. If difficulty is encountered,  
check for ice and snow buildup that may be obstructing the steering  
linkage. Make sure all greaseable components are properly lubricated.  
26  
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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.  
The throttle safety switch is designed to stop the engine whenever all  
pressure is removed from the throttle lever and the throttle cable or  
valve does not return to the normal closed position.  
If excessive play develops in the  
throttle cable, the safety switch may  
be activated and will prevent the  
engine from starting. If the engine  
doesn't start and throttle safety switch  
malfunction is suspected, return the  
machine to an authorized Polaris  
dealer for service.  
.03 in. (.8 mm)  
27  
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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 mar-  
ginal lubrication and are not recommended. Do not operate the snowmo-  
bile with a damaged track.  
WARNING  
Operating the snowmobile with a damaged track will increase the possibility of  
additional track damage and/or failure. This could cause loss of control, result-  
ing in severe injury or death. Always inspect for damage before using the  
snowmobile.  
NOTE: Track damage or failure caused by operation under poor lubrication  
conditions will void the track warranty.  
28  
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ADULT SECTION  
Operation Warnings  
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. Use just enough throttle to rotate the  
track and warm up the engine.  
n Do not operate with drive chain guard removed  
WARNING  
The drive chain guard is designed to protect the operator from metal parts in  
the event of a drive chain failure. Although the chance of failure is extremely  
remote, do not defeat the purpose of the guard by removing it. It is provided  
for the safety of the child.  
29  
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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 physi-  
cal skills. Persons with cognitive or physical disabilities who operate this vehi-  
cle have an increased risk of overturns and loss of control, which could result  
in serious injury or death.  
30  
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ADULT SECTION  
Operation Warnings  
n Check brake lever travel  
Depress the brake lever fully.  
Measure the clearance between  
the lever and brake block. Clear-  
ance should be no more than 3/4"  
(1.9 cm).  
3/4" (19 mm)  
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.  
Never operate a snowmobile with the hood open or removed.  
n Check lights  
Start the engine and ensure that both the headlight and taillight operate.  
31  
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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 snow-  
mobile. The riding position may vary as the operator becomes more  
skilled, but under most conditions the proper position is to be seated  
with both feet on the running boards, in a comfortable position for  
proper throttle, brake and steering control.  
WARNING  
This snowmobile is propelled by a revolving track, which must be partially  
exposed for proper operation. Serious injuries may be caused by operator  
carelessness, resulting in hands, feet, hair or clothing becoming entangled in  
the track. Teach the child to respect this machine and all moving parts. Teach  
the child that being properly seated is the safest way to stay clear of the track.  
WARNING  
Never hold the snowmobile up or  
stand behind it while warming up  
the track. A loose track or flying  
debris could cause serious per-  
sonal injury or death.  
32  
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ADULT SECTION  
Operation Warnings  
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. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
4
E
of a circle surrounding the letter E, followed by the  
distinguishing number of the country which has  
granted approval. The approval number and serial  
number will also be displayed on the label.  
051039  
0006.31  
Eye Protection  
Do not depend on eyeglasses or sunglasses for eye protection. When-  
ever riding a Polaris vehicle, always wear shatterproof goggles or use a  
shatterproof helmet face shield. Polaris recommends wearing approved  
Personal Protective Equipment (PPE) bearing markings such as VESC  
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.  
33  
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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. Instead, stop the engine, raise the hood, make the adjustment,  
secure shields and guards, secure the hood, and then re-start the engine to  
check its operation. The same is true of track alignment. If the track must be  
re-aligned, it is recommended that this service be performed by your dealer.  
n Know limitations of machine and skills of driver  
The operator should be aware that most areas have laws governing  
snowmobile operation and that these laws should be followed. They  
have been established for the protection of all snowmobile riders. Many  
local organizations offer a snowmobile safety course for children.  
Check with local authorities to locate providers of this service.  
This vehicle is intended for daylight use only. Check both the headlight  
and taillight to ensure proper operation.  
IMPORTANT: The headlight and taillight are intended only to increase  
the visibility of the snowmobile during daylight operation. Do not oper-  
ate this snowmobile in the dark.  
34  
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ADULT SECTION  
Operation Warnings  
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 oper-  
ators know and understand them. Make sure they know how to drive and  
control the snowmobile before you allow them to drive longer super-  
vised distances. Teach them proper snowmobile courtesy.  
It's a good idea to predetermine some hand signals as a way to commu-  
nicate with a child while giving instruction. It may be difficult for a  
child to hear your voice over the sound of the snowmobile and through a  
helmet.  
Teach the operator that the sound of the engine will make it difficult to  
hear the sound of approaching vehicles. Do not allow a child to operate  
the snowmobile on or near roads and railroad tracks.  
Teach operators what it means to drive defensively. Never tailgate and  
always allow ample stopping distances.  
n Be alert for obstacles  
Wire fences are a serious hazard. Teach  
operators to always be on the alert for  
fences. Single strands are especially dan-  
gerous, since there can be a great distance  
between posts. Ground wires on utility  
poles are also difficult to see. Teach opera-  
tors to reduce speed when traveling near  
poles, posts or other obstacles.  
n Check the weather  
Extremely cold weather can cause frost-  
bite and/or hypothermia. Always be aware  
of weather conditions, especially the  
windchill. See the table on page 39.  
R R  
35  
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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 vehi-  
cle without adult supervision.  
Drive-Away from Parked  
When the snowmobile has been parked for more than a few hours, espe-  
cially overnight, the skis and track may freeze to the ground. Loosen the  
skis and track for the operator. You may have to apply extra throttle ini-  
tially to move the snowmobile. Teach operators not to be afraid of  
applying extra throttle in this situation, but make sure they understand  
that too much throttle could cause the snowmobile to lurch forward.  
Track Lubrication  
Do not operate the snowmobile for more than a few minutes on ground  
surfaces that contain little or no snow. The track needs snow for lubrica-  
tion, so driving in too little snow will result in excessive wear and dam-  
age to the slide rail and track.  
Snow and Ice Build-Up  
Snow and ice buildup in the underhood area can interfere with the steer-  
ing. Manually turn the skis completely to the right and to the left. If dif-  
ficulty is encountered, remove any ice and snow buildup that may be  
obstructing the steering linkage.  
36  
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ADULT SECTION  
Operation Warnings  
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. Restart the engine and drive out of the  
deep snow. Encourage the operator to stay on established riding areas to  
avoid getting stuck.  
Ice and Hard-Packed Surfaces  
Steering and braking control are substantially reduced when operating  
on hard surfaces, hard-packed snow or icy surfaces.Teach your child to  
reduce speed to maintain control in all driving conditions. If necessary,  
limit the maximum speed of the snowmobile as outlined on page 44.  
If ice or slippery conditions are unavoidable, use extreme caution and  
operate at speeds no faster than a walk. The skis need snow to help the  
snowmobile make turns. On hard surfaces the snowmobile will not  
make turns easily. It may be best to stop the engine, dismount, and man-  
ually move the front or rear of the snowmobile to change direction.  
Never make a sharp turn on a slippery surface. The snowmobile may  
skid out of control. Teach all operators to drive only in approved areas  
within the vision of the supervising adult.  
WARNING  
Children must never ride on a frozen body of water. Make sure all operators  
understand that severe injury or death can result if the snowmobile and its  
rider fall through the ice.  
37  
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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. If  
the snowmobile stops while the operator is driving on a hill, the operator  
should dismount on the uphill side of the vehicle. Never dismount or stand on  
the downhill side of a snowmobile.  
Driving Uphill  
Driving uphill should be attempted only by experienced operators.  
1. Stand on the running boards, keeping body weight low and forward.  
2. Accelerate before the start of the climb, releasing the throttle as  
needed to prevent the track from slipping on the snow.  
3. Slow down at the crest of the hill. Be prepared to avoid obstacles,  
sharp drops, or other people or vehicles that may be on the other  
side of the hill.  
Driving Downhill  
Drive downhill slowly. Apply just enough throttle to keep the clutch  
engaged.This will allow engine compression to help slow the machine  
and prevent the snowmobile from rolling freely downhill.  
38  
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ADULT SECTION  
Operation Warnings  
Windchill/Temperature Charts  
The following information is provided to help you determine when tem-  
peratures become dangerous for riding.  
WINDCHILL CHART (_F)  
Wind  
Speed  
in  
Actual Thermometer Reading (_F)  
40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45  
Equivalent Temperature (_F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63  
5
0
MPH  
Calm 40 35 30 25 20 15 10  
5
0
5
36 31 25 19 13  
7
3
0
1
10  
15  
20  
25  
30  
35  
40  
45  
50  
55  
60  
34 27 21 15  
32 25 19 13  
30 24 17 11  
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72  
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77  
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81  
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84  
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87  
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89  
29 23 16  
28 22 15  
28 21 14  
27 20 13  
26 19 12  
26 19 12  
25 18 11  
25 17 10  
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91  
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93  
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95  
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97  
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98  
Frostbite in >> 30 min. 10 min. 5 min.  
WINDCHILL CHART (_C)  
Wind  
Speed  
in  
Actual Thermometer Reading (_C)  
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
Equivalent Temperature (_C)  
KPH  
Calm  
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
-
-7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57  
16  
24  
32  
40  
48  
56  
64  
72  
80  
88  
96  
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62  
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65  
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67  
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69  
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70  
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72  
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73  
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74  
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75  
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76  
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77  
Frostbite in >> 30 min. 10 min. 5 min.  
39  
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ADULT SECTION  
Component Identification  
Seat and  
Storage  
Handlebar  
Windshield  
Headlight  
Hood  
Taillight  
Rear  
Bumper  
Ski  
Snow  
Flap  
Nosepan  
Front  
Bumper  
Rear  
Suspension  
Track  
Trailing Arm  
40  
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ADULT SECTION  
Component Identification  
Brake Lever  
Engine Stop Switch  
Throttle Lever  
Choke  
Knob  
Gas  
Cap  
Recoil Starter  
Handle  
Hood  
Hold-Down  
Strap  
41  
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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 break-  
in 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. Do not operate at full throttle or high speeds during  
the first three hours of use.  
1. Fill the fuel tank with gasoline.  
2. Check the oil level. See page 61.  
3. Drive slowly at first. Select an area that's open and will allow room  
to familiarize yourself with vehicle operation and handling.  
4. Vary the throttle positions. Do not operate at sustained idle.  
5. Perform regular checks on fluid levels, controls and areas outlined  
on the daily pre-ride inspection checklist. See pages 19 and 25.  
6. Change the oil after the first 20 hours of operation.  
42  
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ADULT SECTION  
Operation  
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.  
• Do not overfill the tank. Do not fill the tank neck.  
• If gasoline spills on your skin or clothing, immediately wash it off with soap  
and water and change clothing.  
• If you get gasoline in your eyes or if you swallow gasoline, see your doctor  
immediately.  
• Never start the engine or let it run in an enclosed area. Engine exhaust  
fumes are poisonous and can cause loss of consciousness or death in a  
short time.  
Turn the fuel valve off whenever the vehicle is stored or parked.  
WARNING  
The engine exhaust from this product contains chemicals known to cause  
cancer, birth defects or other reproductive harm. Operate this vehicle only out-  
doors or in well-ventilated areas.  
43  
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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 vehi-  
cle 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.  
Move the governor spring to hole  
#3 for maximum performance  
(highest available speed).  
#3  
Move the governor spring to hole  
#1 for minimum performance  
(lowest available speed).  
#1  
44  
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ADULT SECTION  
Operation  
Starting the Engine  
Never start the engine before performing the Pre-Ride Check. See pages  
19 and 25.  
1. Pull the engine stop switch up to the RUN position.  
2. 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.  
3. Grasp the starter handle and pull slowly until the recoil engages,  
then pull abruptly to start the engine.  
CAUTION  
Extending the starter rope too far or allowing it to snap back into the housing  
will cause damage to the recoil assembly. Do not extend the starter rope to its  
maximum length, and do not drop the rope handle during starting.  
4. If the engine slows or stops, position the choke knob half way in.  
5. Apply the brakes and vary the engine RPM slightly with the throttle  
to aid in warm-up. When the engine idles smoothly, push the choke  
knob all the way in.  
NOTE: To prevent excessive wear on the clutch components, don't engage  
the clutch while performing the warm-up.  
45  
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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.  
THROTTLE  
CONDITION  
SYSTEM  
WHAT IT DOES  
Engine Stop Switch  
Throttle Safety Switch  
Tether Switch  
Brake  
Interrupts ignition circuit  
Interrupts ignition circuit  
Interrupts ignition circuit  
Slows jackshaft  
All  
All  
All  
All  
Choke  
Floods engine  
Half throttle or less  
Daily Storage  
At the end of each ride, park the snow-  
mobile on a level surface. Support the  
rear with an appropriate track stand.  
The track should be suspended approxi-  
mately 4I (10 cm) off the ground.  
Cover the snowmobile with an appro-  
priate snowmobile cover.  
46  
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ADULT SECTION  
Operation  
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 perform-  
ing this procedure. Do not use too much throttle during warm-up or when the  
track is free-hanging.  
1. Start the engine. Allow it to idle for two to three minutes.  
2. Engage the drive system abruptly and allow it to rotate the track  
several revolutions.  
NOTE: In colder weather, the track will need a few more revolutions to fully  
warm it.  
3. Stop the engine. Remove the rear support.  
4. Grasp the skis by their front loops and move them from side to side  
to loosen frozen snow.  
47  
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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 con-  
trol information (ECI) label and a factory-installed emissions informa-  
tion hang tag. These items are required by U.S. Environmental  
Protection Agency regulations. The ECI label is permanently affixed to  
either the right side of the tunnel or the engine recoil cover. The ECI  
label should not be removed, even after you purchase the snowmobile.  
You may remove the factory-installed emissions information hangtag,  
which is intended solely for your use in making a purchasing decision.  
Emission Control Maintenance Requirements  
Your snowmobile is certified to operate on gasoline with a minimum  
octane level of 87 (R+M)/2. The emission control system designation  
per SAE J1930 is EM. If your snowmobile is equipped with a check  
engine light and it comes on, you must take your snowmobile to a quali-  
fied dealer for diagnostic service. Specifications and adjustments for  
engine tune-ups are located in the Service Manual, which is available to  
your qualified service technician. Reverse (if equipped) must not be  
engaged during engine tune-ups.  
Owner's Responsibilities  
Please read the Snowmobile Engine Emissions Limited Warranty on  
page 92, and read the maintenance section of your owner's manual. You  
are responsible for ensuring that the specified maintenance is per-  
formed, including the emission-related maintenance outlined in these  
sections of the manual.  
Polaris considers the specified maintenance for the spark plugs and oil  
changes to be critical emission-related maintenance. Any qualified  
repair shop or qualified person may maintain, replace, or repair the  
emission control devices or systems on your snowmobile. Polaris rec-  
ommends that you contact an authorized Polaris dealer to perform any  
service that may be necessary.  
48  
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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 out-  
lined in this manual. Record maintenance and service in the Mainte-  
nance 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. These inspections should be performed by a qualified service  
technician.  
All necessary replacement parts and labor incurred, with the exception  
of authorized warranty repairs, become the responsibility of the regis-  
tered owner. If, during the course of the warranty period, part failures  
occur as a result of owner neglect in performing recommended regular  
maintenance, the cost of repairs are the responsibility of the owner.  
Personal safety is critical when attempting to service or make adjust-  
ments to your snowmobile. If you're not familiar with safe service or  
adjustment procedures and the use of tools, or if you don't feel comfort-  
able performing these tasks yourself, contact an authorized Polaris  
dealer for service.  
CAUTION  
Hot components can cause damage to plastic. Always make sure the exhaust  
system and engine have cooled before tipping the snowmobile on its side for  
service or inspection.  
49  
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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.  
ITEM  
SEE  
PAGE  
DAILY  
WEEKLY OR  
BEFORE  
EXTENDED  
PERIOD OF  
OPERATION  
50  
HRS  
100  
HRS  
150  
HRS  
Test engine stop switch  
Test throttle safety switch  
Test tether switch  
20, 25  
27  
X
X
X
X
20  
Test throttle lever  
operation  
19, 26  
Test brake lever  
operation  
19  
56  
26  
31  
--  
X
X
X
X
X
X
Check brake operation  
and adjustment  
Check steering system  
operation  
Check operation of  
headlight and taillight  
Clean dust and debris  
from engine  
Check ski skags, replace  
when worn to 1/2 original  
diameter  
71  
Inspect fuel lines, replace  
as needed  
54  
X
X
Check engine oil level  
Oil the drive chain  
20, 61  
60  
Every 10 Hrs  
Every 10 Hrs  
Check track tension,  
tighten if necessary  
63  
Grease the clutch  
Change oil  
73  
62  
Every 15 Hrs  
At 20 Hrs  
X
X
X
50  
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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  
Check track condition  
65  
67  
59  
X
X
X
Check drive chain  
tension  
Check and tighten any  
loose suspension  
mounting bolts  
72  
X
Tighten ski saddle and  
spindle bolts if loose  
--  
--  
X
X
Check front and rear  
limiter strap condition,  
tighten loose bolts  
Check slider thickness,  
replace when worn (see  
dealer)  
68  
X
Tighten rear idler wheel  
bolts if loose  
--  
X
X
X
Check spark plug  
condition  
52  
56  
Check for brake cable  
wear and adjustment  
Throttle cable pivot slug  
58  
--  
X
X
X
X
X
X
Lubricate steering post  
support bracket and pivot  
(aerosol)  
Grease ski spindles  
73  
73  
X
X
X
X
X
X
Lubricate ski bushings to  
spindle area  
Grease lower steering  
post pivot  
--  
X
X
X
X
X
X
Grease rear suspension  
pivot shafts  
72  
Lubricate throttle cable  
58  
58  
X
X
X
X
Lubricate choke slide and  
cable  
Inspect exhaust pipe for  
cracks or damage  
54  
X
X
X
51  
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ADULT SECTION  
Maintenance  
Spark Plugs  
A new engine can cause temporary spark plug fouling due to the preser-  
vative 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 recom-  
mended 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.  
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. 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.  
Spark Plug Removal and Replacement  
1. Stop the engine.  
2. Remove the spark plug cap.  
3. Using the special wrench provided in the tool pouch, rotate the  
spark plug counterclockwise to remove it.  
4. Reverse the procedure for spark plug installation. Torque to 12-14  
ft. lbs. (16-19 Nm).  
52  
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ADULT SECTION  
Maintenance  
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 indi-  
cates 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. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil, use  
of non-recommended oil, improper use of the choke, or incorrect carbu-  
retion adjustments.  
53  
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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 deteriora-  
tion 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 dam-  
age. 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 grom-  
mets.  
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 run-  
ning.  
54  
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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. A  
mixture too rich (too much fuel, too little air) is also unfavorable  
because it can foul plugs and cause generally poor engine performance.  
All carburetors have been pre-set at the factory for adequate fuel supply.  
Higher altitude operation may require different adjustment and settings.  
The number stamped in the end of the main jet indicates the jet size that  
was installed at the time of manufacture. For questions about optional  
jetting for conditions in your area, see your Polaris dealer.  
Correct setup provides engine RPM within its given power band at full  
throttle settings and also provides maximum efficiency and operation at  
all other throttle openings. See your dealer for carburetor adjustments,  
which may include the following:  
• Carburetor component changes for specific altitude and ambient tem-  
peratures  
• Choke adjustment  
• Air screw settings (if applicable)  
• Idle RPM adjustments  
• Throttle safety switch inspections and service  
• Throttle block-to-throttle flipper clearance adjustment  
CAUTION  
Improper carburetor adjustments can result in safety hazards as well as seri-  
ous engine damage. We recommend that all carburetor adjustments be per-  
formed by your Polaris dealer.  
55  
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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.  
WARNING  
Improper brake adjustment can result in brake failure, which could result in  
severe injury or death. Perform the adjustment procedures exactly as outlined,  
or see your Polaris dealer for service.  
1. Slide the two rubber protector covers back to expose the cable  
adjuster.  
2. Using an 8mm wrench to hold the barrel nut, loosen the jam nut  
with a 10mm wrench.  
3. With your left hand, grasp the cables as close to the adjuster as pos-  
sible. Use your right hand to rotate the barrel nut until you have  
reached the proper brake lever adjustment.  
Jam Nut  
Barrel Nut  
Cables  
Rubber Covers  
56  
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ADULT SECTION  
Maintenance  
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.  
1/4-3/8" (6-10 mm)  
Band Bolt Nut  
5. Tighten the adjuster jam nut and  
slide the rubber protectors onto  
the adjuster.  
6. The brake band is adjusted  
correctly when brake lever  
freeplay is 1/4- 3/8" (6-10 mm)  
and clearance between the brake  
lever and block with the lever  
fully depressed is no more than  
3/4" (19 mm). Torque the band  
bolt nut to 6 ft. lbs. (8 Nm).  
57  
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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 possi-  
bility of the choke becoming fro-  
zen.  
Throttle Cable Pivot Slug  
Lubricate the throttle cable pivot  
slug every 50 hours or twice a year  
using an aerosol lubricant.  
Pivot Slug  
58  
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ADULT SECTION  
Maintenance  
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. Inspect the sprockets  
as they also wear and often need replacement when the chain is  
replaced.  
Muffler Mount Bracket  
1" (25 mm)  
1/8" (3 mm)  
Chain Tensioner  
59  
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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.  
Point A  
Engine  
Carburetor  
Track  
Point B  
Chain  
Drive Shaft  
Torque Converter  
(Centrifugal Clutch)  
60  
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ADULT SECTION  
Maintenance  
Engine Oil  
Oil Recommendations  
Polaris recommends the use of Performance Synthetic 4-Stroke oil (PS-  
4 or PS-4 Plus) for this engine. PS-4 has been specially formulated for  
use in Polaris 4-cycle snowmobile engines. It's a fully synthetic, high  
performance, multi-viscosity oil designed to provide the ultimate in  
lubrication performance and protection.  
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. Always change the oil any time it's  
contaminated with water, fuel or debris.  
CAUTION  
Mixing brands or using a non-recommended oil may cause serious engine  
damage. Always use the recommended oil. Never substitute or mix oil brands.  
Oil Level  
Maintain the oil level between the upper and lower marks on the dip-  
stick.  
1. Position the vehicle on a level  
surface.  
2. Stop the engine.  
3. Remove the dipstick and wipe  
it dry with a clean shop towel.  
4. Insert the dipstick into the oil  
fill hole completely, but do  
not thread it.  
Dipstick  
5. Remove the dipstick and view  
the oil level.  
6. If the oil level is below the  
lower mark on the dipstick,  
Safe  
Range  
{
add the recommended oil to  
the upper mark.  
Upper  
Mark  
Lower  
Mark  
61  
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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.  
Drain Plug  
Dipstick  
4. Remove the dipstick and  
wipe it dry with a clean  
shop towel.  
NOTE: The oil will drain faster with the dipstick removed.  
5. Allow the oil to drain completely.  
6. Reinstall the drain plug and sealing washer.  
7. Using a long funnel, pour 20 oz. (.6 l) of the recommended oil into  
the oil fill hole.  
8. Insert the dipstick into the oil fill hole completely, but do not thread  
it.  
9. Remove the dipstick and view the oil level.  
10. If the oil level is below the lower mark on the dipstick, add the rec-  
ommended oil to the upper mark.  
62  
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ADULT SECTION  
Maintenance  
Track Tension  
Track adjustment is critical for proper handling. Always maintain cor-  
rect tension and alignment.  
1. Operate the snow-  
mobile to warm up  
the track.  
Adjusting  
Screw  
2. Stop the engine.  
3. Support the rear of  
the snowmobile  
slightly off the  
ground with an  
appropriate snow-  
mobile support.  
Idler  
Shaft  
Bolt  
4. Hang a 10-pound  
(4.5 kg) weight 8  
inches (20 cm) from  
the center of the  
8" (20 cm)  
10 lbs.  
(4.5 kg)  
rear idler wheel.  
5. Measure the distance between wear surface of the track clip and the  
plastic slider at the point where the weight is hanging. Deflection at  
this point should be 3/4" (19 mm).  
6. If the track tension needs adjustment, follow the procedure on page  
64.  
63  
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ADULT SECTION  
Maintenance  
Track Tension Adjustment  
1. Loosen the rear idler shaft bolt.  
2. Tighten or loosen the track adjusting screws to provide equal adjust-  
ment 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 mov-  
ing parts to avoid serious personal injury. Make sure the track contains no  
objects that could be thrown out while the track is rotating. Keep clear of track.  
This includes but is not limited to hands, tools, feet and clothing. Make sure no  
one is standing close to the machine while the track is rotating.  
4. Start the engine and slowly rotate the track at least five revolutions.  
Allow the track to stop rotating by itself (do not apply brakes).  
5. Check and adjust track alignment. See page 65.  
6. Tighten the idler shaft bolt. Torque to 35-40 ft. lbs. (47-54 Nm).  
7. Readjust the toe block to proper spacing and tighten.  
64  
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ADULT SECTION  
Maintenance  
Track Alignment  
Check track alignment at the intervals outlined in the periodic mainte-  
nance 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 mov-  
ing parts to avoid serious personal injury. Make sure the track contains no  
objects that could be thrown out while the track is rotating. Keep clear of track.  
This includes but is not limited to hands, tools, feet and clothing. Make sure no  
one is standing close to the machine while the track is rotating.  
1. Support the rear of the  
snowmobile slightly off the  
ground with an appropriate  
snowmobile support.  
2. Start the engine and apply a  
small amount of throttle  
until the track turns slowly  
at least five complete revo-  
lutions. Stop the engine.  
3. Inspect track alignment by  
looking through the track  
Rail  
windows to make sure the  
Slider  
rails are evenly spaced on  
each side. If the track runs  
to the left, loosen the left  
idler wheel mounting bolt and tighten the left track adjusting bolt. If  
the track runs to the right, loosen the right idler wheel mounting bolt  
and tighten the right track adjusting bolt.  
4. After adjustments are complete, tighten the locknuts and idler shaft  
bolts. Torque to 35-40 ft. lbs. (47-54 Nm).  
5. Repeat step 2 to verify proper alignment.  
65  
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ADULT SECTION  
Maintenance  
Track Warm Up  
After storing your snowmobile  
outside overnight, warm up the  
track before driving the snow-  
mobile. 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. Abruptly engage the clutch, allowing the track to turn for several  
revolutions.  
4. Release the throttle and apply the brakes.  
5. Stop the engine.  
6. Lower the rear of the snowmobile to the ground while the engine is  
off.  
66  
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ADULT SECTION  
Maintenance  
Track Inspection  
Check track condition at the intervals outlined in the periodic mainte-  
nance chart beginning on page 50.  
WARNING  
Inspecting the track while the engine  
is running can result in serious per-  
sonal 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. Support the rear of the  
Common Breakage Areas  
snowmobile slightly off the  
ground with an appropriate  
snowmobile support.  
2. Rotate the track by hand to  
check for wear or damage.  
3. Carefully examine the  
track along the entire  
length of each track rod,  
bending the track and  
inspecting for breakage.  
NOTE: The three most common  
places where breakage  
occurs are shown in the  
Lug  
Track  
Window  
illustration.  
4. Check the track clips and  
tighten any loose clips. If  
any rod damage is found, install a new track.  
NOTE: This snowmobile track has molded-in track clips. It is common for a  
thin layer of rubber to detach from the clip area and peel off during ini-  
tial use.  
67  
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ADULT SECTION  
Maintenance  
Slider Replacement  
Minimum  
Thickness  
Polaris rail slides have a wear limit  
indicator groove to indicate the  
minimum permissible slide thick-  
ness. Replace the rail slides if they  
are worn to the top of the groove at  
any point along their length. Fail-  
ure to do so may result in perma-  
nent damage to the track or rails.  
Replace when  
worn to top of  
groove  
Track Lubrication  
Track failure, loss of vehicle control and braking ability can result from  
extended use of this vehicle on surfaces providing marginal lubrication  
between the slider and track guide clips. Examples of marginal lubrica-  
tion would include lakes without snow cover, icy trails and no-snow  
conditions.  
The slide rail is designed to operate in conditions with adequate snow  
cover in order to provide sufficient lubrication. Excessive wear indicates  
insufficient lubrication. A new slider can cause faster heat build up in  
limited lubrication than a used slider, resulting in excessive wear.  
NOTE: Track damage or failure caused by operation on ice or poor lubrication  
conditions may void the track warranty.  
Steering System  
The steering systems on Polaris snowmobiles can be adjusted with ski  
toe alignment. Improper toe alignment can cause erratic steering. See  
your dealer for adjustments.  
WARNING  
Improper alignment or adjustment may cause loss of steering control, result-  
ing in serious injury or death. Do not attempt to change the ski alignment. See  
your Polaris dealer.  
68  
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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. The measurement  
between the skis at point X should be 1/8I (3 mm) greater than the mea-  
surement at point Y.  
NOTE: If the skis are misaligned, we recommend that your dealer make the  
necessary adjustments.  
X
Y
+
+
+
+
+
+
69  
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ADULT SECTION  
Maintenance  
Handlebar Adjustment  
1. Slide the handlebar pad  
upward to access the  
adjuster bolts. If additional  
room is required, unzip one  
of the handlebar pad zippers  
and roll the pad to the side.  
Lower  
Nut  
2. Remove the upper flange  
nut and carriage bolt.  
3. Loosen the lower flange nut  
only enough so the bracket  
can move freely.  
Upper Bolt  
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. (20-23 Nm).  
7. Reinstall the handlebar pad.  
70  
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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  
and other bare terrain.  
Skag  
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.  
WARNING  
Worn skis and/or skags will adversely affect handling and can cause loss of  
vehicle control, which can lead to serious injury or death. Replace worn skis  
and/or skags when inspection reveals wear.  
Skag Replacement  
1. Raise and support the front of the machine so the skis are approxi-  
mately 6" (15 cm) off the ground.  
2. Remove the attaching nuts and pry the skag downward.  
3. Remove the forward portion of the skag.  
4. Reverse this procedure for new skag installation.  
NOTE: If the rear idler wheel  
Rear Idler  
assembly washers are  
Wheel  
removed, be sure they are  
Washer  
reinstalled with the domed  
side of the washer facing  
outward as shown.  
Domed Side  
Outward  
71  
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ADULT SECTION  
Maintenance  
Lubrication Recommendations  
Suspension  
To maintain rider comfort and to retard wear of the pivot shafts, lubri-  
cate 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. A  
grease gun kit complete with grease and adaptors is available to lubri-  
cate all fittings on Polaris snowmobiles. See page 82 for the part num-  
bers of Polaris products.  
IMPORTANT: Make it a weekly practice to check for loose bolts and  
nuts on the suspension system. If any loose bolts are found on the rail be  
sure to clean the threads and apply LOCTITE 262 before tightening.  
Suspension Components  
Carrier  
Wheel  
Torsion  
Springs  
Rear Limiter Strap  
Torsion Spring  
Sleeve  
Spacer  
Front Limiter  
Strap  
Idler  
Wheel  
Toe Guard  
+
Adjuster  
Bolts  
Rail  
Rail Bumper  
+
Slider  
Torque Arm  
72  
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ADULT SECTION  
Maintenance  
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 and tie rod ends with a light coat of oil or grease.  
Remove the spindle shafts and lubricate the bushings on the top and bot-  
tom of the trailing arm.  
Lubricate throttle and brake controls and cables with Polaris Premium  
All Season Grease. Force a small amount of lubricant down the cable.  
See page 58.  
Bearings  
Always grease drive shaft clutch side bearings with a high quality bear-  
ing grease to prevent corrosion, which will destroy the bearings.  
Electrical Connections  
Separate the electrical connector blocks and clean corrosive build-up  
from the connectors. Lubricate the blocks with dielectric grease and re-  
connect. Replace worn or frayed electrical wire and connectors. Be sure  
wiring harnesses are properly secured away from sharp edges, steering  
linkage, moving parts, and hot exhaust components.  
73  
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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. Use a professional-type washing cloth, cleaning the upper body first  
and the lower parts last.  
2. Rinse with clean water frequently.  
3. Dry surfaces with a chamois to prevent water spots.  
Washing Tips  
• Avoid the use of harsh cleaners, which can scratch the finish.  
• Do not use a power washer to clean the vehicle.  
NOTE: If a high pressure car wash is used (not recommended), grease all  
zerk fittings immediately after washing. Remove the spindle shafts and  
lubricate the bushings on the top and bottom of the trailing arm. Also  
run the vehicle to evaporate any water that might have entered the  
engine or exhaust system.  
• Do not use medium to heavy duty compounds on the finish.  
• Always use clean cloths and pads for cleaning and polishing. Old or  
reused cloths and pads may contain dirt particles that will scratch the  
finish.  
• If any decal becomes illegible or comes off, contact your Polaris  
dealer to purchase a replacement. Replacement safety decals are pro-  
vided by Polaris at no charge  
Waxing the Vehicle  
Your snowmobile can be waxed with any high quality brand of automo-  
tive paste wax. Avoid the use of harsh cleaners since they can scratch  
the body finish.  
74  
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ADULT SECTION  
Maintenance  
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. Slowly pull the recoil starter to turn the engine over two or three  
times.  
7. Reinstall the spark plug.  
8. Rotate the piston to bottom dead center (BDC) and  
9. Slowly pull the recoil starter handle until resistance is felt. Leave it  
in that position.  
10. Clean the engine thoroughly with an oiled cloth.  
NOTE: If Polaris fuel system additive is not used, the fuel tank, fuel lines, and  
carburetor should be completely drained of gasoline. Observe all fire  
safety rules when draining the carburetor. Review the fuel-related  
warnings on page 43. To eliminate any fuel remaining in the carbure-  
tor, run the engine until it stops.  
75  
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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.  
NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and  
removes carbon deposits from pistons, rings, valves and exhaust sys-  
tems.  
3. Start the engine. Allow it to idle for five minutes to disperse addi-  
tives through the entire fuel system.  
4. Turn the fuel valve off.  
76  
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ADULT SECTION  
Maintenance  
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. It should be covered with a fabric snowmobile cover. Plastic  
covers can cause condensation to form and may damage some snowmo-  
bile components.  
77  
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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.  
Towing  
Do not pull or tow any person or object behind this snowmobile. If a  
disabled snowmobile must be towed by another snowmobile, attach the  
tow rope to the spindles of the disabled snowmobile, not to the ski toe  
loops.  
Emergency Preparation  
For your added protection, carry the following items in your snowmo-  
bile when traveling farther than a five-minute walk from home.  
• Extra Spark Plugs  
• First Aid Kit  
• Winter Survival Kit  
• Extra Gloves  
• Owner's Manual  
78  
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TROUBLESHOOTING  
Engine Turns Over, Fails to Start  
Contact your Polaris dealer for service if you're unable to identify solu-  
tions using the following chart.  
Possible Cause  
Solution  
Tether switch not engaged  
Engine stop switch not on  
Throttle safety switch malfunction  
Out of fuel  
Install tether switch/strap  
Pull stop switch up to RUN position  
See your Polaris dealer  
Refuel  
Clogged fuel valve or filter  
Water is present in fuel  
Fuel valve is off  
Inspect and clean or replace  
Drain the fuel system and refuel  
Turn the fuel valve on  
Old or non-recommended fuel  
Fouled or defective spark plug(s)  
No spark to spark plug  
Replace with new fuel  
Inspect plug(s), replace if necessary  
Inspect plug(s), verify stop switch is  
on  
Overuse of choke  
Mechanical failure  
Inspect, clean and/or replace spark  
plugs  
See your Polaris dealer  
79  
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SPECIFICATIONS  
Capacities and Dimensions  
Body Style  
Mini Indy  
Rider/Weight Capacity  
Dry Weight  
Fuel Tank Capacity  
Engine Oil Capacity  
Height  
Length  
Width  
Track Length  
Track Width  
Brake Type  
1/140 lbs. (63.5 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  
Ski Center Distance  
Clutch Type  
30 in. (76.2 cm)  
Centrifugal  
Drive Chain Length  
#40  
Suspension  
Front Type  
IFS  
IFS Shock Type  
Rear Type  
Mini  
Mini Indy  
Engine and Cooling  
Engine Model Number  
Alternator Output  
Bore x Stroke  
Displacement  
Carburetor Model  
Idle RPM +/- 200  
Main Jet  
EH122PM018  
50 watt @ 3600 rpm  
60 x 43 mm  
121 cc  
Mikuni BV18  
1650  
70  
50  
NOTE: These carburetor  
settings are to be used in  
conjunction with the jetting  
chart on the following page,  
which is based on the  
Pilot Jet  
Cutaway  
170 Throttle  
Valve  
recommended fuel octane.  
Fuel Screw  
Pilot Air Jet  
Cooling  
1.75 Turns  
1.3 mm  
Air  
1
Cylinders  
Ignition Timing  
Ignition Type  
Spark Plug/Gap  
23° BTDC @ 3600 RPM  
Flywheel Magneto (solid state)  
NGK BR6ES/.028" (.70 mm)  
Recommended Engine Oil PS-4 or PS-4 Plus  
Recommended Fuel Octane Minimum 87 octane non-oxygenated or 89  
octane oxygenated  
80  
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SPECIFICATIONS  
Carburetor Jetting  
AMBIENT TEMPERATURE  
ALTITUDE 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  
Meters (Feet)  
(-34° to -23°C) (-26°C to -15°C) (-18° to -7°C)  
(-9° to +2°C)  
(-1° to +10°C)  
(+7° to +18°C)  
-25°F  
+60°F  
(-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  
67.5  
45  
600-1200  
(2000-4000)  
70  
50  
70  
50  
70  
50  
67.5  
50  
67.5  
50  
67.5  
50  
65  
45  
65  
45  
1200-1800  
(4000-6000)  
67.5  
50  
67.5  
50  
67.5  
50  
65  
50  
65  
50  
65  
45  
62.5  
45  
62.5  
45  
1800-2400  
(6000-8000)  
65  
50  
65  
50  
65  
50  
65  
50  
65  
45  
62.5  
45  
62.5  
45  
60  
45  
2400-3000  
(8000-10000)  
65  
50  
65  
50  
62.5  
50  
62.5  
45  
60  
45  
60  
45  
60  
45  
60  
45  
3000-3700  
(10000-12000)  
62.5  
50  
62.5  
50  
60  
45  
60  
45  
60  
45  
57.5  
45  
57.5  
45  
57.5  
45  
81  
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POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricants  
Fogging Oil (12 oz. Aerosol)  
2870791  
2874865  
2874866  
2876244  
2876245  
Performance Synthetic 4-Stroke (PS-4) Oil (qt.)  
Performance Synthetic 4-Stroke (PS-4) Oil (gal.)  
Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.)  
Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.)  
Gearcase/Transmission Lubricants  
Premium Synthetic Gearcase Lubricant (qt.)  
Premium Front Gearcase Fluid (8 oz.)  
Premium Demand Drive Hub Fluid (8 oz.)  
Grease/Specialized Lubricants  
Grease Gun Kit, Premium All Season (3 oz.)  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Dielectric Grease (Nyogelt)  
2873602  
2871653  
2871654  
2871312  
2871322  
2871423  
2871329  
Coolant  
2871323  
2871534  
Anitfreeze, 60/40 Premix (gal.)  
Anitfreeze, 60/40 Premix (qt.)  
Additives/Miscellaneous  
2871326  
2870652  
2872189  
2872893  
2870505  
2872889  
2872890  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
DOT 4 Brake Fluid (12 oz.)  
Engine Degreaser (12 oz.)  
Isopropyl  
Brake and Clutch Cleaner  
Carb and Throttle Body Cleaner  
82  
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WARRANTY  
Service and Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty information con-  
tained 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 con-  
tained in this manual. Your dealer is also familiar with Polaris policies and pro-  
cedures and will be happy to assist you.  
When contacting us about parts, service, or warranty, always provide the fol-  
lowing information:  
1. Serial number  
2. Model number  
3. Dealer name  
4. Date of purchase  
5. Details of trouble experienced  
6. Length of time and conditions of operation  
7. Previous correspondence  
Use the page provided near the front of your Owner's Manual to record the  
identification numbers of your snowmobile and its engine.  
Polaris Customer Service  
United States: 1-763-417-8650  
Canada: 1-204-925-7100  
83  
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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. Polaris warranty will provide all dealerships with a monthly updated list of  
all stolen units to further monitor thefts.  
3. Polaris warranty will aid in notifying the proper owner when a unit is  
recovered.  
84  
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WARRANTY  
Limited Warranty  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-  
ITED 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 war-  
ranty period, through a Polaris dealer.  
Registration  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and setup of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
setup will void your warranty coverage.  
Warranty Coverage and Exclusions  
Limitations of warranties and remedies  
This warranty excludes any failures not caused by a defect in material or workmanship.  
The warranty does not cover accidental damage, normal wear and tear, abuse or  
improper handling. The warranty also does not cover any snowmobile that has been  
structurally altered, neglected, improperly maintained, used for racing or used for pur-  
poses other than for which it was manufactured. The warranty does not cover any dam-  
ages that occur during trailer transit or as a result of unauthorized service or parts. In  
addition, this warranty does not cover physical damage to paint or finish, stress cracks,  
tearing or puncturing of upholstery material, corrosion or defects in parts, components  
or the snowmobile due to fire, explosions or any other cause beyond Polaris' control.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the snowmobile.  
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option,  
repair or replacement of any defective materials, or components or products. THE REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL  
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL  
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF  
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-  
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion or limitation of incidental or consequential damages or implied warranties, so the  
above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
85  
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WARRANTY  
Limitations of warranties and remedies  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR  
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-  
RANTIES 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.  
How to Obtain Warranty Service  
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-  
rized to repair Polaris snowmobiles. When requesting warranty service you must present  
your copy of the Warranty Registration form to the dealer. (The cost of transportation to  
and from the dealer is YOUR responsibility). Polaris recommends that you use your  
original selling dealer; however, you may use any Polaris Servicing Dealer to perform  
warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact the  
appropriate personnel at Polaris if additional assistance is needed.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-  
ommend the use of Polaris engine oil.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
86  
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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.  
Use of the recommended Polaris products for lubrication and maintenance as directed by  
the Owner's manual is highly recommended. Should a failure occur during the warranty  
period resulting from the use of non-recommended products, warranty coverage may be  
denied.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination. The following items are excluded from warranty con-  
sideration if the failure was due to wear or not the direct result of a defect:  
Skis  
Ski wear rods  
Tracks  
Slide rails  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Idler wheels  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered "consumable," meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Fuel  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Sealants  
Hotel fees  
Meals  
Towing charges  
Mileage  
Rentals/Loss of product use  
Shipping/ handling fees  
Product pick-up/delivery  
Loss of vacation/personal time  
This warranty also excludes failures resulting from improper lubrication; improper  
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold  
or contamination; operator error or abuse; improper component alignment, tension,  
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign  
substance ingestion/contamination; improper maintenance; modified components; use  
of aftermarket components resulting in failure; unauthorized repairs; repairs made after  
the warranty period expires or by an unauthorized repair center; use of the product in  
competition or for commercial purposes. Warranty will not apply to any product which  
has been damaged by abuse, accident, fire or any other casualty not determined a defect  
of materials or workmanship.  
87  
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WARRANTY  
Polaris Second Year Engine Service Contract  
Second Year Engine Service Contract is standard on all eligible new and unused snow-  
mobiles 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 transfer-  
able 120 days after the original purchase date, free of charge, through any Polaris snow-  
mobile dealer. Coverage on Snow Check units is automatic. Although you do not  
receive a warranty card, your dealership should have printed a copy of the warranty reg-  
istration form. This form is your proof of warranty.  
Consumer Exclusions  
Each repair visit after the first twelve months of standard warranty coverage is sub-  
ject to a $50 deductible.  
The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under  
this program.  
Snowmobiles used for commercial purposes or for racing are excluded from cover-  
age.  
88  
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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 addi-  
tional 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.  
A partial list of items excluded from coverage includes:  
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris' con-  
trol.  
Damage caused by the failure of other components of the snowmobile.  
Failures caused by improper fuel or oil.  
Piston seizures, unless caused by a defective engine component.  
Failures caused due to improper adjustments.  
Failure due to unauthorized service.  
Failures due to lack of service as required in the owner's manual or Polaris updates.  
This includes off-season storage as listed in the owner's manual.  
Failure due to use of unauthorized parts or modifications.  
Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
Cooling system coverage is limited to the water pump assembly and components,  
fan, fan bearings, temperature sensor, gasket and seals.  
Non wear related throttle body parts are covered. The fuel pump is covered.  
Clutches and related clutch parts, including but not limited to, the drive belt, are  
excluded from coverage.  
Electrical components are excluded from coverage.  
Gearcases and transmissions are excluded from coverage.  
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WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-  
TION.  
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.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer's authorized location.  
This policy does not apply to Safety Recalls.  
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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.  
Outside the Country where your vehicle was purchased:  
If you are traveling temporarily outside the country where your vehicle was purchased,  
you should take your vehicle to an authorized Polaris dealer. You must show the dealer  
photo identification from the country of the selling dealer's authorized location as proof  
of residence. Upon residence verification, the servicing dealer will be authorized to per-  
form the warranty repair.  
If You Move:  
If you move to another country, be sure to contact Polaris Customer Assistance and the  
customs department of the destination country before you move. Vehicles importation  
rules vary considerably from country to country. You may be required to present docu-  
mentation of your move to Polaris Industries in order to continue your warranty cover-  
age. You may also be required to obtain documentation from Polaris Industries in order  
to register your vehicle in your new country.  
If Purchased From A Private Party:  
If you purchase a Polaris product from a private citizen outside of the country in which  
the vehicle was originally purchased, all warranty coverage will be denied.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance (see page 83).  
91  
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WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
This snowmobile engine emissions limited warranty is in addition to the Polaris stan-  
dard 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.  
Polaris warrants that the engine is free from defects in materials and workmanship that  
would cause it to fail to meet these regulations. The warranty period for this emissions  
certified snowmobile engine starts on the date when the engine is first purchased and  
continues for 4000 kilometers (2485 miles) of vehicle travel, 200 hours of operation, or  
30 calendar months, whichever comes first.  
This engine emissions limited warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. This includes compo-  
nents whose failure increases the snowmobile engine's emissions. To the extent they are  
present on your snowmobile engine, this includes electronic controls, fuel injection  
components, exhaust-gas recirculation system components, and aftertreatment system  
components. Replacing or repairing other components not covered by this warranty is  
the responsibility of the snowmobile owner.  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or prod-  
ucts.  
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY  
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.  
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,  
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER  
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-  
TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WAR-  
RANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES  
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE  
LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN.  
POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS  
WARRANTY.  
92  
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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 lim-  
ited 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 any engine that has been used in racing competition. This limited  
warranty also does not cover physical damage, corrosion or defects caused by fire,  
explosions or other similar causes beyond the control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris can deny an emissions warranty claim if any specified critical  
emissions-related maintenance is not performed. Performance of other scheduled main-  
tenance is strongly recommended, but is not necessary to keep the emissions-related  
warranty valid.  
Any qualified repair shop or qualified person may maintain, replace, or repair the emis-  
sion control devices or systems on your snowmobile. Polaris recommends that you con-  
tact an authorized Polaris dealer to perform any service that may be necessary.  
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts  
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering  
with emission controls is prohibited by federal law and may result in civil penalties.  
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MAINTENANCE LOG  
Present this section of your manual to your dealer each time your snow-  
mobile is serviced. This will provide you and future owners with an  
accurate log of maintenance and services performed on the snowmobile.  
DATE  
HOURS  
50  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
100  
150  
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MAINTENANCE LOG  
DATE  
HOURS  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
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INDEX  
A
H
Air Pollution . . . . . . . . . . . . . . . . . . . 7  
Handlebar Adjustment. . . . . . . . . . . . 70  
Hood Hold-Down Strap. . . . . . . . . . . 15  
B
I
Bearings. . . . . . . . . . . . . . . . . . . . . . 73  
Brake Cable Adjustment . . . . . . . 56-57  
Brake Lever . . . . . . . . . . . . . . . . . . . 14  
Brake Lever Travel . . . . . . . . . . . . . 56  
Break-In Period . . . . . . . . . . . . . . . . 42  
Ice and Hard-Packed Surfaces. . . . . . 37  
K
Know Your Snowmobile. . . . . . . 14-18  
C
L
Carburetor . . . . . . . . . . . . . . . . . . . . 55  
Carburetor Jetting . . . . . . . . . . . . . . 81  
Chain Tensioner. . . . . . . . . . . . . . . . 59  
Choke Knob. . . . . . . . . . . . . . . . . . . 15  
Choke/Cable Lubrication. . . . . . . . . 58  
Component Identification . . . . . . 40-41  
Controls and Linkage. . . . . . . . . . . . 73  
Customer Service. . . . . . . . . . . . . . . 83  
Lubrication  
Bearings. . . . . . . . . . . . . . . . . . . 73  
Controls and Linkage. . . . . . . . . 73  
Electrical Connections. . . . . . . . 73  
Lubrication Recommendations . . 72-73  
M
Maintenance. . . . . . . . . . . . . . . . . 49-78  
Maintenance Chart. . . . . . . . . . . . 50-51  
Maintenance Log. . . . . . . . . . . . . 94-95  
Maintenance Program . . . . . . . . . 12, 49  
Modifications. . . . . . . . . . . . . . . . . . . 11  
D
Daily Storage . . . . . . . . . . . . . . . . . . 46  
Drive-Away from Parked . . . . . . . . 36  
Driveline Lubrication. . . . . . . . . . . . 60  
Driving on Hills. . . . . . . . . . . . . . . . 38  
Driving Responsibly . . . . . . . . . . . . 36  
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
E
O
Electrical Connections. . . . . . . . . . . 73  
Emergency Preparation . . . . . . . . . . 78  
Emission Control Information. . . . . 48  
Engine Break-In. . . . . . . . . . . . . . . . 42  
Engine Emissions Warranty . . . . 92-93  
Engine Oil . . . . . . . . . . . . . . . . . . 61-62  
Engine Starting . . . . . . . . . . . . . . . . 45  
Engine Stop Switch . . . . . . . . . . . . . 14  
Environment . . . . . . . . . . . . . . . . . . 7-8  
Exhaust System . . . . . . . . . . . . . . . . 54  
Oil Change. . . . . . . . . . . . . . . . . . . . . 62  
Oil Level . . . . . . . . . . . . . . . . . . . . . . 61  
Oil Recommendations . . . . . . . . . . . . 61  
Oil, Engine. . . . . . . . . . . . . . . . . . 61-62  
Operation . . . . . . . . . . . . . . . . . . . 43-47  
Operation Warnings. . . . . . . . . . . 29-39  
P
Polaris Products. . . . . . . . . . . . . . . . . 82  
Pre-Ride Check . . . . . . . . . . . . . . 19-28  
Pre-Ride Warm-Up . . . . . . . . . . . . . . 47  
F
Fall Tune-Up . . . . . . . . . . . . . . . . . . 78  
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 43  
Fuel Lines . . . . . . . . . . . . . . . . . . . . 54  
Fuel Valve . . . . . . . . . . . . . . . . . . . . 54  
R
Recoil Starter. . . . . . . . . . . . . . . . . . . 15  
Registration, Warranty. . . . . . . . . . . . 85  
Riding Rules . . . . . . . . . . . . . . . . 21-24  
G
Gas Cap . . . . . . . . . . . . . . . . . . . . . . 15  
96  
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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 . . . . . . . . . . . . . . . . . 52-53  
Speed/Performance Regulation. . . . . 44  
Starting the Engine . . . . . . . . . . . . . . 45  
Steering Adjustment . . . . . . . . . . . . . 69  
Steering Inspection . . . . . . . . . . . . . . 69  
Steering System . . . . . . . . . . . . . . . . 68  
Stop Switch. . . . . . . . . . . . . . . . . . . . 14  
Stopping . . . . . . . . . . . . . . . . . . . . . . 18  
Stopping Procedures . . . . . . . . . . . . . 46  
Storage . . . . . . . . . . . . . . . . . 46, 75-77  
Engine Fogging. . . . . . . . . . . . . 75  
Tether Strap/Switch . . . . . . . . . . . . . 15  
Throttle Cable Lubrication . . . . . . . . 58  
Throttle Cable Pivot Slug . . . . . . . . . 58  
Throttle Lever . . . . . . . . . . . . . . . . . . 14  
Towing . . . . . . . . . . . . . . . . . . . . . . . 78  
Track Alignment. . . . . . . . . . . . . . . . 65  
Track Inspection . . . . . . . . . . . . . . . . 67  
Track Lubrication . . . . . . . . . . . . 36, 68  
Track Tension . . . . . . . . . . . . . . . . . . 63  
Track Tension Adjustment . . . . . . . . 64  
Transporting the Snowmobile. . . . . . 78  
Troubleshooting . . . . . . . . . . . . . . . . 79  
V
Vehicle Identification Numbers . . . . . 9  
W
Washing the Vehicle. . . . . . . . . . . . . 74  
Waxing the Vehicle . . . . . . . . . . . . . 74  
Windchill . . . . . . . . . . . . . . . . . . . . . 39  
Stabilize the Fuel . . . . . . . . . . . 76  
Storage Area . . . . . . . . . . . . . . . 77  
Track and Suspension . . . . . . . . 77  
Suspension Components. . . . . . . . . . 72  
Suspension Lubrication. . . . . . . . . . . 72  
97  
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