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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 owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
Copyright 2006 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. 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.
2007 440 IQ Owner’s Manual P/N 9920432
2
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features and Controls . . . . . . . . . . . . . . . . . . . . . 24
This section illustrates the locations of your snowmobile’s controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . . . 42
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
This section explains proper engine break-in, operation of features and
operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 100
This section is a quick reference guide to solving problems.
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . 111
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3
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INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when sold.
Some of the illustrations and photos used in this manual are general
representations. Your model may differ.
Follow the maintenance program outlined in this manual. Preventive
maintenance ensures that critical components of the snowmobile are
inspected by your dealer at specific mileage intervals.
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.
Protect and preserve your right to ride by joining your local trail riding
clubs.
4
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INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may
not be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission
levels of two-stroke engines. We expect our efforts to lead to the
reduction of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
5
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INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile’s identification numbers in the spaces
provided.
Vehicle Model Number:
Tunnel VIN:
(lower right side of the tunnel)
Engine Serial Number:
(right front side of engine crankcase)
6
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
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.
7
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SAFETY
Operator Safety
Follow the recommended maintenance program outlined beginning on
page 59 of this manual to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific
mileage intervals.
WARNING
Driving a snowmobile requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving or
riding as a passenger. They will reduce your alertness and slow
your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra
caution to ensure operator safety. Make sure your snowmobile is
in excellent operating condition at all times. Always check major
and vital safety components before every ride.
All Polaris snowmobiles are designed and tested to provide safe
operation when used as directed. Failure of critical machine
components may result from operation with any modifications,
especially those that increase speed or power. DO NOT
MODIFY YOUR MACHINE. The snowmobile may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.
8
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation.
WARNING
Serious injuries may result if hands, feet, or
clothing become entangled in the track.
Be alert when riding, and remain properly
seated to stay clear of the track.
Never hold the snowmobile up or
stand behind it while warming up the
track. A loose track or flying debris
could cause serious injury or death.
We recommend having your dealer
perform all track service and
alignment procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Stop the engine,
raise the hood, make the adjustment, secure shields and guards, secure
the hood, and then restart the engine to check its operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting
adjustments.
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under most conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING
Improper riding position may reduce control and could result in
serious injury or death. Always be properly seated and in position
to control your vehicle.
9
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SAFETY
Operator Safety
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular telephone.
For added protection, carry the following items on your snowmobile at
all times:
SSpare Drive Belt
STow Rope
SFuel Deicer
STrail Map
SFirst Aid Kit
SExtra Set of Spark Plugs
SExtra Oil
SWinter Survival Kit
SOwner’s Manual
Riding Apparel
Be prepared, be warm and be
comfortable when riding. Be
aware of the weather
forecast, especially the
windchill, and dress
accordingly. See the chart
on page 19.
WARNING
Avoid wearing loose
clothing or long
scarves, which can
become entangled in
moving parts and
cause serious injury.
Always wear an
approved helmet and
eye protection.
10
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SAFETY
Operator Safety
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have
an increased risk of loss of control, which could result in serious injury
or death.
Rider Capacity
Your Polaris snowmobile is designed for a single rider only. Do not
carry a passenger.
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious
injury or death. Always reduce speed when driving at night or in
inclement weather.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the
trail ahead. Multiplying speed (MPH) by 1.5 will equal the
approximate number of feet per second your machine travels. If your
speed is 40 MPH, your machine is traveling about 60 feet per second.
If you look back for only two seconds, your machine will travel about
120 feet. If your speed is 60 MPH, your machine will travel about 180
feet.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t over-drive your headlight beam.
Always be able to bring your machine to a stop in the distance
illuminated by the headlight.
11
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SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you’re snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or
highways. Steep embankments may also
hide your view. Always leave yourself a
way out.
Variances in snow depth and/or water
currents may result in uneven ice
thickness. Always check with local
residents or authorities for general information on conditions when
traveling on lakes and streams that are strange to you. Before riding
your machine on a frozen body of water, be sure the ice is thick enough
to support the machine and its operator, as well as the force created by
a moving vehicle. You may drown if you and the snowmobile break
through the ice.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
12
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
S Take an avalanche class
S Travel with experienced people
S Travel on designated trails
S Make sure each person is equipped with
a shovel, probe and avalanche beacon.
You don’t have to be snowmobiling on a slope for an avalanche to
occur. Be aware that all of the snow is connected. You may be riding
on a flat slope or snow covered road, but if the snowpack above is
unstable enough you can trigger an avalanche on a steeper slope above
you. Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit either
the American Avalanche Association online at
www.americanavalancheassociation.org or the U.S. Forest Service
National Avalanche Center at www.avalanche.org.
13
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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING
Ice and snow build-up may interfere with the steering of your
machine, resulting in serious injury or death. Keep the
underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure
ice and snow are not interfering with full left and right steering. If
difficulty is encountered, remove ice and snow build-up that may be
obstructing the steering linkage.
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution.
Driving on ice or hard-packed snow reduces steering and braking
control, which may result in loss of control and serious injury or
death. Slow down and use extra caution when operating on
slippery surfaces.
Driving Downhill
When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep
the clutch engaged, allowing the engine’s compression to help slow the
machine and keep it from rolling freely downhill.
WARNING
When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.
14
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SAFETY
Operator Safety
Driving in Hilly Terrain
WARNING
Climbing a hill or crossing the face of a slope may result in loss of
balance and machine roll-over, causing serious injury or death.
Use caution and good judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the machine to
maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops or other people or vehicles that may be on the
other side of the hill.
If you’re unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn’t possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine
and set the parking brake (if equipped). Keeping away from the
downhill side of the machine, pull the rear of the snowmobile around
and point the front end and skis downhill. Remount the machine,
restart the engine, release the parking brake, and descend the hill
carefully.
15
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SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is
dynamically balanced before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the machine into motion, but always operate
within safety limits.
Maneuverability
While much control and maneuverability is achieved through the
steering system and skis, maximum control is achieved by the shifting
of your body weight. Maneuverability will change for lighter operators
or machines designed to carry a load.
16
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SAFETY
Operator Safety
Inadequate Snow Conditions
WARNING
Do not drive for prolonged periods on blacktop, gravel, or ice.
Doing so could cause irreversible track damage and lead to
serious injury.
Since snow provides the only lubrication for the power slide
suspension and, on liquid cooled models, cooling for the engine,
adequate snow cover is a requirement for operation of your machine.
Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine.
If the machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when
the throttle is opened, the snowmobile will be able to climb up and
over the snow.
CAUTION
When operating on icy surfaces or hard-packed snow, avoid
overheating the slide rail and track. Lack of lubrication and
cooling will cause overheating of the slide rail and track, resulting
in premature wear and failure. If frequently operating in low
cooling conditions, see your dealer for an optional wheel kit that
will reduce the wear from overheating.
17
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SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile
conditions may become dangerous if operators drive improperly. If
you’re new to snowmobiling, acquaint yourself with the machine and
with what it will and won’t do under various conditions. Even
seasoned drivers should spend some time getting the feel for a machine
before attempting ambitious maneuvers.
S A snowmobile depends on the rider’s body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
S Before allowing someone else use your snowmobile, know the ex-
tent of their operating skills. Check to see if they’ve taken a snow-
mobile safety course and have an operator’s certificate. For their
protection, as well as yours, make sure they take a snowmobile safe-
ty course. Everyone can benefit from the course.
S Don’t “jump” your snowmobile. Jumping may injure your back be-
cause of spinal compression. The seat and suspension of your snow-
mobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.
S Be courteous to oncoming traffic by dimming your headlights and
reducing your speed. Your snowmobile is equipped with a high out-
put headlamp system that may cause discomfort to operators of on-
coming vehicles when on high beam.
S When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Allow ample stopping distances, and keep track of those
following you. Drive defensively to avoid accidents.
18
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when
temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
in
Actual Thermometer Reading (°F)
MPH
40 35 30 25 20 15 10
5
0
-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
Calm 40 35 30 25 20 15 10
5
0
5
36 31 25 19 13
7
3
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 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
0
4
-2
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
3
1
0
-1
-2
-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
-8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-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.
WIND CHILL CHART (°C)
Wind
Speed
in
Actual Thermometer Reading (°C)
KPH
5
2
-1
-4
-7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Equivalent Temperature (°C)
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.
19
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your
protection. Read and follow the instructions of the decals on the
snowmobile carefully. If any of the decals depicted in this manual
differ from the decals on your snowmobile, always read and follow the
instructions of the decals on the snowmobile.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found under the hood on the clutch cover:
WARNING
AVERTISSEMENT
Pressure Cap Warning
This warning decal is found on the
coolant bottle cover of liquid cooled
models:
20
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SAFETY
Safety Decals and Locations
Track Warning
The track warning decal is located on the rear of the tunnel:
+
Passenger Warning
This snowmobile is designed for one operator only. A “No Passenger”
warning decal is located on the lower console:
+
21
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SAFETY
Safety Decals and Locations
Operation Warning
+
22
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SAFETY
Safety Decals and Locations
Operation Warning
23
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FEATURES AND CONTROLS
2
3
4
1
12
5
6
7
11
8
1. Brake Lever
2. Tachometer
13
3. Temperature Light
4. Engine Stop Switch
5. Throttle Control
6. Choke Control
9
7. Recoil Starter Handle
8. Fuel Filler Cap
9. Park Brake Lock
10. Headlight Dimmer Switch
11. Handlebar Grip Warmer/
Thumbwarmer Switch
12. Tether Switch
10
14
13. Master Cylinder
14. Dragont Ignition System Switch
24
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FEATURES AND CONTROLS
1
2
3
11
10
4
5
9
8
7
6
1. Handlebar
2. Windshield
3. Headlight
4. Hood
5. Nosepan
6. Skis
7. Track
8. Suspension
9. Snow Flap
10. Taillights
11. Seat
25
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FEATURES AND CONTROLS
Polaris DRAGON Ignition System
Your snowmobile is equipped with an ignition system feature that
improves competition performance by increasing exhaust system
temperature. The DRAGON Ignition System provides maximum
“holeshot” performance for racing applications.
WARNING
DRAGON mode increases the exhaust system temperature and
causes engine misfire and backfire. Flammable materials and
vapors may ignite and result in fire and explosion, which may
cause serious injury, death or property damage. Read the
Owner’s Manual. Always follow all instructions and warnings.
DRAGON Mode Facts
S The DRAGON Ignition System is intended for competition use on
closed courses by experienced riders only.
S There is no benefit to using DRAGON mode for normal trail riding.
S Unnecessary, extended or excessive use of DRAGON mode can re-
sult in severe engine damage, which is excluded from Polaris war-
ranty coverage.
S DRAGON mode usually heats up the exhaust system within 5 to 20
seconds, depending upon the initial temperature of the exhaust sys-
tem.
S Two different sounds may be heard when using DRAGON mode.
One sound is an erratic misfire that may be heard when the exhaust
system is heating up. The other sound is a consistent misfire (with a
slight rise in engine RPM) when the exhaust system is at target oper-
ating temperature.
S DRAGON mode maintains the engine speed between 4500 and 5100
RPM.
S Be sure that the clutch engages at 5300 RPM or above to prevent
forward creep of the vehicle. See your dealer if the clutch needs ad-
justment.
S Please refer to the Polaris jetting chart and use the recommended jet
for current temperatures as this system is sensitive to jet changes.
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FEATURES AND CONTROLS
Polaris DRAGON Ignition System
DRAGON Mode Operation
1. Warm up the engine and
track. See page 52.
2. When staged at the starting
line, depress and hold the
DRAGON (horn) button on
the left handlebar (1).
3. Slowly advance the throttle
to the wide-open position
while keeping the button
depressed.
4. Release the button when the
start flag drops.
1
NOTE: The vehicle will launch
forward at wide-open
throttle.
27
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THE PERFECT FIT
IQ Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight,
vehicle speed, riding style, and trail conditions. We recommend
starting with factory settings and then customizing each adjustment
individually to suit rider preference. The machine should be
methodically tested, one change at a time, under the same conditions
(trail and snow conditions, vehicle speed, riding position, etc.) after
each adjustment until the best ride is achieved.
IFS Components
1. Skis
2. Spindles
3. Front shocks and springs
4. Control arms
IFS Adjustment Options
S Front shock spring preload
S Compression damping (see
page 30)
2
S Optional springs
S Optional shock valving (if
equipped with Walker/Evans
shocks)
4
3
S Toe (ski alignment) (see page
92)
1
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THE PERFECT FIT
IQ Front Suspension Adjustments
WARNING
Always verify ski alignment before making adjustments to the
IFS. See page 92 to check alignment. If the skis are misaligned,
see your dealer, as the camber adjustment may also be affected.
The tension at which the shock coil spring is set is called spring
preload. For the best ride, the spring preload should be set as low as
possible to use the full travel of the ski shock, with occasional light
bottoming. To determine if your machine is using full travel of the ski
shock, push the o-ring travel indicator down as far as it will go on the
shock rod and test ride the machine. The o-ring will move up on the
rod in direct relation to the amount of travel. If the shock travel is full,
the bumper will be seated at the top of the shock.
Shock Absorber Components
1. Retainer
2. Shock Rod
3. O-Ring Travel Indicator
4. Body
5. Threaded Spring Preload Adjuster Nut
6. Reservoir
4
5
1
3
2
6
29
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THE PERFECT FIT
IQ Front Suspension Adjustments
Front Shock Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing spring
B
A
preload will decrease ski-to-ground
pressure. When adjusting, be sure the
springs on both the left and right sides of
the machine are at the same adjustment.
A = Low preload
B = High preload
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
rear suspension.
Decreasing the spring preload too much
may allow the upper spring retainer to fall
off.
NOTE: Always leave at least one
thread showing above the nut.
1. Grasp the spring and turn it to the left to increase preload.
2. Turn the spring to the right to decrease preload.
Shock Damping (Walker/Evans Shock)
1
Turn the adjuster (1) clockwise to
increase stiffness. Turn the adjuster
counterclockwise to decrease stiffness.
30
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THE PERFECT FIT
IQ Front Suspension Adjustments
Shock Valving
Walker/Evans shocks can be revalved if spring preload alone isn’t
sufficient and further adjustment is desired to control suspension
stiffness.
WARNING
Changing shock valving on Walker/Evans shocks requires special
tools and a sound knowledge of mechanical theory, tool use, and
shop procedures to perform the work safely and correctly.
Shocks contain high-pressure nitrogen gas. Use extreme caution
when handling high-pressure service equipment. We recommend
that this work be performed by a Polaris dealer.
Front Springs
For models without externally adjustable or revalvable shocks, the
front springs can be changed if spring preload alone isn’t sufficient and
further adjustment is desired to control suspension stiffness. See your
Polaris dealer for more information.
31
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THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and
deliver excellent performance for a given set of conditions. However,
all suspension designs and adjustments involve a compromise, or
trade-off. For example, a suspension set up for snow-cross racing
would provide a very stiff ride on the trail. A suspension set up for
trail riding would bottom out harshly on a snow-cross course.
A decal outlining rear suspension set-up options is located either under
the hood or on the clutch cover. It provides a guideline for initial
suspension set-up. Additional adjustments can be made from this
point. Make adjustments to one area at a time so you can evaluate the
change. For further assistance, see your dealer.
Suspension Performance Tips
S Rider weight usually determines the position at which the spring pre-
load should be set. However, this may vary with riding style. With
a little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
S A new slider will offer improved performance over a worn slider. It
can also improve top speed.
S When riding on ice or hard-packed snow, adding a set of bogie
wheels to the rail may enhance the machine’s performance. Bogie
wheel kits are available from your dealer.
S Polaris offers track kits for improved flotation in deep snow. See
your dealer for assistance.
NOTE: Keep the suspension pivot points lubricated. This will reduce
moisture and rust build-up and ensure proper function of the
suspension components. Grease rear suspension pivots
before adjusting the rear suspension. Refer to Suspension
Maintenance beginning on page 94.
32
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Rear Torsion Spring Tension
To adjust rear torsion spring tension, rotate the three-position cam
using the engine spark plug tool. Different rate torsion springs are
available if a firmer ride is desired. Contact your dealer for more
information.
The following information is provided only as a guideline to be used
for initial suspension set-up. Your set-up may vary based on your
desired riding style.
2a
2b
c
1
1 - Turn the knob toward the “S” for a softer ride
Turn the knob toward the “H” for a stiffer ride
2a -Soft Tension - long end of cam to front
2b -Medium tension - short end of cam up
2c -Firm tension - long end of cam up
33
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Suspension Coupling
On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of
suspension coupling, these torque arms could move independently of
each other. Rear suspension coupling links the movement of the front
and rear torque arms to each other. There are two types of rear
suspension coupling.
Front Rear Scissor Stop (FRSS)
The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of
independence between the movement of the front torque arm and the
rear torque arm.
When hitting a bump, the front torque arm starts to compress. The
FRSS links that movement to the rear torque arm, causing it to
compress and raise the rear suspension up as one, allowing the
suspension to hit the bump only once and eliminating kickback. Your
FRSS is preset at the factory.
34
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Rear Rear Scissor Stop (RRSS)
The rear rear scissor stop (RRSS) couples the movement of the rear
torque arm with the front torque arm and limits the amount of
independent movement between the rear torque and the front torque
arm.
Adjusting the RRSS either allows more weight to transfer to the rear
for more traction, or allows less weight to transfer to the rear, resulting
in improved cornering performance. An adjustment dot is located on
the RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop - Attributes
Moving the RRSS to a higher position, or forward hole, will have the
following effects on the suspension:
S Reduced weight transfer.
S Improved chatter bump ride.
S Improved cornering performance.
35
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Weight Transfer During Acceleration
IQ Rear Rear Scissor Stop (RRSS)
The preferred method for controlling weight
transfer during acceleration of the IQ rear
suspension is by adjusting the RRSS. Use the
scissor stop tool (1) located in your tool kit to
make the adjustments.
1
To decrease weight transfer under acceleration
(for improved cornering), rotate the RRSS to
a higher position.
To increase weight transfer or ski lift during acceleration, move the
RRSS to the rearward upper position. The RRSS may also be rotated to
a lower position for even more weight transfer if desired.
A - Low Position - This setting will increase weight transfer.
B - Medium Position - This setting is the production setting and will
provide the best overall trail riding.
C - High Position - This setting will decrease weight transfer.
D - Rearward Upper Position (optional hole location) - This setting
will increase weight transfer.
NOTE: Your dealer can help you with initial set-up and additional
set-up instructions to help you achieve an optimum ride.
z
C
A
D
B
36
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THE PERFECT FIT
Handlebar Adjustments
Handlebar with Riser Block
1. Remove the handlebar
cover to expose the
handlebar mounting hardware.
2. Using a 1/4” Allen wrench,
loosen the two bolts on the
bottom of the riser or the two
bolts on the top of the riser,
depending on the type of
adjustment required.
3. Adjust the handlebar to the
desired angle. Be sure the
handlebar, brake lever and
throttle lever operate smoothly
and do not hit the gas tank,
windshield or any other part of
the machine when the handlebar is turned fully to the left or right.
4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-17.6
Nm).
5. Replace the handlebar cover.
37
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THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable. See your dealer for a complete list of
accessories.
Use only Polaris parts and accessories on your Polaris snowmobile.
Use of unapproved parts and accessories may result in:
S Non-compliance with government/industry requirements
S Voiding of warranty
S Personal injury to self or others
This applies to, but is not limited to brakes, clutches, fuel systems, and
exhaust systems.
NOTE: Exhaust systems are critical safety areas that must use
approved Polaris parts. Please see your Polaris dealer for
service.
38
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THE PERFECT FIT
Accessories
Traction Products
Another way to tailor your machine is to install traction products. See
your dealer about installing studs and/or carbides. Many tracks with
deep lug designs cannot be studded, but your dealer will be able to
offer advice and assistance.
NOTE: Before equipping your machine with traction products, be
aware of the laws in your area pertaining to the use of
traction products.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering
ability may be reduced on hard-packed snow or ice.
A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. The addition of carbide skags is
recommended with studded tracks to help maintain proper vehicle
steering and control. Similarly, if your machine is equipped with
carbide skags or you’re adding them, it may be necessary to add track
studs to maintain proper vehicle control. Proper balance must be
maintained between the number of studs and the length of carbide on
skags. The more studs used, the longer the carbide on the skags should
be. See your dealer’s track studding chart for recommended studding
and skags.
Inspect skags and studs frequently. Worn studs or skags may reduce
steering and braking control on hard-packed snow and ice. Replace
worn studs and skags to maintain proper balance and vehicle control.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are
available. See your dealer for more information.
39
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THE PERFECT FIT
Accessories
CAUTION
Aggressive studding patterns may require grinding protruding
stud bolts flush to prevent idler wheel damage. Maintain track
tension on studded tracks on the tight side of the spec to prevent
heat exchanger damage. Center of stud must be at least 1 1/8″
(2.86 cm) from outside edge of the track.
CAUTION
If traction products are added to the track, wear strips must be
installed in the tunnel to avoid excessive wear.
Never add shims to the wear strip. Track damage will result
because of lack of clearance between upper carrier wheels and
track.
Use of studs longer than the recommended length on machines
equipped with center coolers will result in center cooler damage
or damage to the tunnel.
Use only Polaris traction products on your snowmobile. Track
warranties are void if track damage or failure results from improper or
excessive stud installation or the use of non-Polaris traction products.
WARNING
Loss of control can result in serious personal injury or death.
Proper balance of traction products on the skis and track must be
maintained to obtain proper vehicle control on hard-packed snow
or ice. See your dealer for assistance.
40
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THE PERFECT FIT
Accessories
Wear Strips
Polaris IQ models are manufactured with tunnel wear strips or wear
strip coolers installed. To avoid excessive tunnel wear, tunnel wear
strips must be installed whenever track studding is used.
Wear strips are designed for a specific stud length. See your dealer’s
studding chart for recommended traction accessories.
Components as viewed from the rear of the track:
1. Top of tunnel
2. Wear strip
3. Track
4. Wearstrip mounting holes
1
2
4
3
CAUTION
Whenever wear strips are relocated, be sure there’s adequate
stud clearance to the heat exchangers. Lack of clearance may
result in damage to heat exchangers.
41
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PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the
referenced pages. Look for a checkmark (n) on the referenced pages
to locate the pre-ride inspection items.
See Page
84, 85
46
Item
Drive Belt Condition
Steering System
Recoil Rope
46
Coolant Level
73
Park Brake Lock/Brake Lever/Brake System
Auxiliary Shut-Off Switch (Engine Stop Switch)
Taillight/Brakelight/Headlight
Suspension Mounting Bolts
Skags (Wear Bars)
45, 77
47
47
--
39, 93
46
Hood Straps/Latches
Seat Latches (if equipped)
Throttle Lever
--
43
Rear Wheel Idler Bolts
89, 94
47
Tether Switch/Strap
Track Alignment/Condition
Slider Condition
89, 90
94
Chaincase Oil Level
66
42
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PRE-RIDE INSPECTIONS
Before Starting the Engine
WARNING
Worn, damaged, or malfunctioning components may cause
serious injury or death. Before starting the engine, check all
components to be sure of proper operation.
Read and Understand Your Owner’s Manual
Read the Owner’s Manual completely and refer to it often. We’ve
attempted to provide as much information as possible to alert you to
the safety requirements of snowmobiling.
n Check Throttle and Brake for Proper Operation
The throttle and brake are the primary controls of your snowmobile. If
either should malfunction, loss of control could result.
Make sure the throttle lever compresses evenly and smoothly. The
lever 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 immediately.
The need for a properly functioning brake is critical. Your snowmobile
is equipped with the highest quality brake system available. Check the
brakes for correct operation before starting the engine.
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Hydraulic Brakes
Always check the
following items to assure
proper operation before
starting the engine.
1/2″ (1.3 cm)
Brake Lever Travel
Squeeze the brake lever.
It should move no closer
to the handgrip than 1/2″
(1.3 cm). A smaller
distance indicates low brake fluid level or air in the hydraulic system.
Refer to the brake bleeding information on page 80.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 79.
Check for the presence of air in the fluid system. See page 80 for more
information, or see your dealer for service.
WARNING
Continued use of “spongy” brakes may cause a complete loss of
brakes, which could result in serious injury or death. Always have
the brakes serviced at the first sign of sponginess.
44
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Park Brake Lever Lock
Your snowmobile may have a park brake lever lock located over the
brake lever. Use the brake lever lock only when you want the machine
to remain stationary; for example, when parked on an incline for a
period of five minutes or less. To apply the lock, squeeze the brake
handle and push forward on the brake lever lock. Hold the lock
forward and release the brake handle.
If the brake handle is squeezed tightly enough, the lock will move
freely into place. Do not force the lock or it may break. To release the
lock, squeeze the brake handle until the lever returns to the unlock
position. The park brake light on the console will light up when the
park brake lever lock is set and the engine is running. It will also be lit
when the service brake is in use. If the park brake light does not come
on when the park brake or service brake is in use, have it serviced by
your dealer.
2
3
1. Brake Lever
1
2. Park Brake Lever Lock
3. Master Cylinder
Reservoir / Cover
WARNING
If the park brake lever lock is partially or entirely engaged while
riding, overheating of the brakes could occur, resulting in brake
damage. In extreme cases it could cause a fire, which could
result in serious injury or death.
45
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Check for Proper Operation of Steering System
Manually turn the skis completely to the right and to the left. If any
difficulty is encountered, check for ice and snow build-up that may be
obstructing the steering linkage. Make sure all greasable components
are properly lubricated.
n Track Inspection
WARNING
Always inspect the track for damage before using the vehicle.
Operating the snowmobile with a damaged track increases the
possibility of track failure, which could cause loss of control
resulting in serious injury or death.
Use of traction products such as studs increases the possibility of track
damage and/or failure. Driving at high speeds for extended periods of
time in marginal lubrication could severely damage track rods, break
track edges, and cause other track damage. Examples of marginal
lubrication would include frozen bodies of water without snow cover,
icy trails, and no-snow conditions.
NOTE: Track damage or failure caused by operation on ice or poor
lubrication conditions voids the track warranty.
n Check Hood Latches
The hood of the snowmobile protects the operator from moving parts
as well as aiding in sound emission control and other functions. Under
no circumstances should your snowmobile be operated with the hood
open or removed. Always ensure that the hood straps are in good
condition and that the latches are securely in place before operating the
snowmobile.
n Check Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure
the knot securing the rope inside the handle is secure. If excessive
wear is found, see your Polaris dealer for replacement.
46
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PRE-RIDE INSPECTIONS
Start the Engine and Check
n Engine Stop Switch: Check the auxiliary shut-off switch for
proper operation. Push down to stop the engine. Pull up to release
and allow starting of the engine.
n Tether Switch: Make sure the engine shuts off when the tether is
removed from the switch.
n Lighting: Check the headlight (high and low beam), taillight, and
brake light for normal operation.
n Check Surroundings to Verify Clear Operating Area: Make
sure you have a clear area all around your snowmobile, including
an area clear of bystanders. There’s always the possibility of some
sideways vehicle movement, of applying a little more throttle than
intended, or of debris being thrown by the track. If the
surrounding area is clear you before you start, you can devote your
full attention to operating the snowmobile.
47
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OPERATION
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first 3.5 gallons (13.2 l) of gasoline with 16 oz. (473 ml) of the
recommended 2-cycle racing oil (28:1). Premix future gasoline at 32:1.
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 for extended periods during the first three
hours of use. Vary the throttle openings and machine speeds to
reduce friction on all close-fitting machined parts, allowing them
to break in slowly without damage.
Use of any lubricants other than those recommended by Polaris
may cause serious engine damage. We recommend the use of
Polaris lubricants for your vehicle.
Drive with extra caution during the break-in period. Perform
regular checks on fluid levels, lines, and all other important areas
of the machine.
48
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OPERATION
Oil Recommendations
The only source of engine lubrication for your engine comes from
lubrication added to the fuel. We highly recommend the use of only
Polaris products. We’re continuously testing lubricants and provide the
highest performance products available for your snowmobile’s engine.
We recommend the use of Polaris 2-Cycle Racing Oil for your
snowmobile. See page 99 for the part numbers of Polaris products.
Never mix brands of oil. Serious chemical reactions can cause system
blockage, resulting in serious engine damage. They may also be
incompatible and the result could be sludge formation, filter blockage,
and reduced cold weather flow rates. All Polaris oils are compatible
with each other.
Fuel Recommendations
110 Octane
The fuel used in your Polaris engine is as important to engine life and
performance as the lubricant used. Always use 110 octane fuel for the
440 IQ snowmobile.
CAUTION
Using fuels with a lower than recommended octane or operating
with obstructed fuel systems will result in serious and costly
engine damage. Always use the recommended fuels for your
machine.
49
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OPERATION
Fuel
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well
ventilated area.
S Do not overfill the tank. Do not fill the tank neck.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area. Engine
exhaust fumes are poisonous and can cause loss of conscious-
ness or death in a short time.
S Turn the fuel valve off whenever the snowmobile 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 outdoors or in well-ventilated areas.
50
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OPERATION
Starting the Engine
WARNING
Before starting the engine, always refer to all safety warnings
pertaining to snowmobile operation. Never start your snowmobile
without checking all components to be sure of proper operation.
See Check Before Starting the Engine beginning on page 43.
Starting a Cold Engine
Do not depress the throttle until the engine starts.
1. Attach the tether cord to the tether switch.
2. Pull the kill switch (shut-off switch) up to RUN.
3. Flip the choke toggle to FULL ON.
4. Grasp the starter handle and pull slowly until the recoil engages;
then pull abruptly to start the engine.
CAUTION
Don’t pull the starter rope to full extended position or allow it to
snap back into the housing. Damage may result.
To avoid personal injury and/or engine damage, do not operate
the recoil pull-rope starter while the engine is running.
5. After the engine starts, flip the choke toggle to the OFF position.
If the engine slows or wants to stop, use intermittent choking to the
HALF ON position.
6. Warm up the engine before operating. See page 52.
Starting a Warm Engine
1. Attach the tether cord to the tether switch.
2. Pull the kill switch (shut-off switch) up to RUN.
3. Grasp the starter handle and pull slowly until the recoil engages;
then pull abruptly to start the engine.
If the engine does not start on the first pull, slightly depress the throttle
with your left hand (no more than 1/4″ open), and pull the rope with
your right hand. When the engine starts, immediately release the
throttle.
51
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OPERATION
Slide Rail and Track Cooling
CAUTION
Inadequate cooling and lubrication will lead to overheating of the
slide rail and track, resulting in premature wear and failure.
Reduce speeds and frequently drive into fresh snow to allow
adequate cooling and polishing of the slide rail and track
surfaces. Avoid operating on ice, hard-packed surfaces or roads.
Engine and Track Warm-Up
WARNING
A loose track or flying debris could cause serious personal injury
or death. Stand clear of the front of the machine and the moving
track. Never hold the snowmobile up or stand behind it while
warming up the track. Do not use excessive throttle during
warm-up or when the track is free-hanging. Be sure the rear
support is stable.
WARNING
Use of traction products such as studs, ice growsers, etc. will
increase the possibility of track damage and/or failure. This could
cause loss of control, resulting in serious injury or death. Always
inspect for track damage before operating the snowmobile.
Follow these steps to ensure proper
warm-up of the engine, drive train and
track.
1. Use an appropriate stand to securely
support the rear of the snowmobile at
the rear bumper. The track should be
approximately 4″ (10 cm) off the
ground.
52
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OPERATION
Engine and Track Warm-Up
2. Start the engine and allow it to warm up two to three minutes.
3. Depress the throttle abruptly and allow the track to rotate several
revolutions.
NOTE: It will take longer to warm up the track sufficiently during
colder outdoor temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the machine to the ground.
5. Grasp the skis by their front loops and move them from side to
side. This will loosen frozen snow from the ski bottoms, allowing
the machine to move forward more easily.
6. The engine, drive system and track are now properly warmed up
and the machine may be driven following normal safety practices.
53
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OPERATION
Carburetion
Proper carburetor adjustment is critical. A lean mixture (too much air,
too little fuel) may result in piston burning, bearing failure, or
complete engine failure. A rich mixture (too much fuel, too little air)
may foul plugs and cause generally poor engine performance.
A lean mixture may be caused by things like fuel line restrictions,
foreign matter in the carburetor or clogged fuel filters. A rich mixture
may be caused by snow build-up on the pre-filter in the air intake
system. Either condition may be caused by improper carburetor
adjustment.
WARNING
Improper carburetor adjustments may result in operator safety
hazards as well as serious engine damage. Always have your
Polaris dealer perform any carburetor adjustments.
54
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OPERATION
Carburetion
Jetting Guidelines
Changes in altitude and temperature affect air density, which is the
amount of oxygen available for combustion. In low elevations and
cold temperatures, the air has more oxygen. In higher elevations and
higher temperatures, the air is less dense.
Carburetors on most Polaris models are calibrated for an altitude of
0-2000 ft (0-600 meters) and ambient temperatures between -10 to +10
F (-23 to -12 C). All carburetors must be re-calibrated if operated
outside this production temperature and/or altitude range. The main jet
installed in production is not correct for all altitudes and/or
temperatures.
CAUTION
A main jet that’s too small will cause a lean operating condition
and may cause serious engine damage. Jet the carburetors
carefully for elevation and temperature according to the jetting
charts in your Owner’s Manual Supplement.
NOTE: It’s the owner’s responsibility to ensure that the correct jets
are installed in the machine for a geographical area. Be very
careful when jetting down in warm weather. As the weather
turns colder it will be necessary to re-jet upward to prevent
engine damage. When selecting the proper main jet always
use the lowest elevation and temperature that is likely to be
encountered.
55
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OPERATION
n Engine Stop Switch
1
Push down on the engine stop
switch (1) to stop the engine in an
emergency. To restart the engine,
pull the switch up to the ON
position.
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. Refer to page 56 for more information about
the engine stop switch.
SYSTEM
WHAT IT DOES
THROTTLE
CONDITION
Brake
Choke
Slows jackshaft
All
Floods engine
Half throttle or less
Engine Stop Switch
Tether Switch
Interrupts ignition circuit
Interrupts ignition circuit
All
All
WARNING
Excessive or repetitive use of brakes for high speed stops will
cause an overheated brake system. This overheated condition
could cause sudden loss of brakes and/or fire, resulting in serious
injury or death.
When traveling on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat and
result in brake failure.
56
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OPERATION
Emergency Starting
Your machine is equipped with a tool kit containing essential tools for
emergency use. If the recoil starter system fails, an emergency start
strap is provided in the kit.
WARNING
Serious injury can result from wrapping the start strap around
your hand while using the emergency starting procedure. DO
NOT wrap the start strap around your hand. Keep all bystanders
and loose clothing away from the snowmobile when using the
emergency starting procedure.
To use the emergency start strap:
1. Open the clutch guard.
2. Push on the inner
sheave of the clutch
and rotate clockwise
slightly to relieve belt
tension.
3. Starting at one of the
tower struts, wind the
strap counterclockwise
around the clutch as
shown.
4. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine.
57
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OPERATION
Daily Storage
At the end of each ride, park the
snowmobile on a level surface and
support it at the rear with an appropriate
track stand. The track should be
suspended approximately 4″ (10 cm) off
the ground. Cover the machine with an
appropriate cover.
Towing
WARNING
Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting
in serious injury or death. DO NOT tow toboggans, sleds,
saucers, or any type of vehicle with a rope. Only a stiff metal
pole connecting the towed object and the tow hitch on the
snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2
meters) long to prevent any possibility of contact between the
snowmobile’s track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to
maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it
isn’t possible to use a rigid tow bar, attach the tow rope to the ski
spindles (not to the ski loops) to prevent damage to the steering
components. Remove the drive belt before towing, and have a rider on
the towed snowmobile to operate the brake and steering when
necessary.
CAUTION
Towing a disabled snowmobile with the drive belt in place can
result in serious damage to the engine and drive system. Always
remove the drive belt from a disabled snowmobile before towing.
58
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MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and service checks outlined in this
manual. Record services performed in the Maintenance Record at the
rear of this manual.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km), and 1000 miles (1600 km). These inspections should be
performed by a qualified service technician. For continued optimum
performance and component life, continue maintenance checks at 1000
mile (1600 km) intervals.
All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the
registered 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 adjust your
snowmobile. If you’re not familiar with safe service or adjustment
procedures and the use of tools, or if you don’t feel comfortable
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.
59
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MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.
See
Page
Frequency
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
Clutch
Clutch Offset Alignment
(without belt)
83
I
I
I
Drive Belt Condition
Clutches (disassemble)
Belt Tension
84
83
--
I
C
I
I
C
I
I
C
I
I
I
I
Clutch Sheaves
83
I
I
I
Engine
Engine Mounts
--
--
I
I
I
I
I
I
I
I
Recoil Rope
Engine Mounting Plate
Engine Torque Stop
Cylinder Head Bolts
Cylinder Base Nuts
Ignition Timing BTDC
VES System
--
I
I
I
86
--
I
I
I
I
I
I
I
--
I
I
I
I
--
I
I
I
--
C
I
C
I
C
R
I
I
I
Coolant Level
73
N/A
--
Water Pump Drive Belt
Coolant Hose
I
I
I
I
I
I
I
Heat Exchangers
Coolant Circulation
Coolant Leaks
74
--
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
Spark Plug Condition
Exhaust Pipe
68
72
72
I
I
I
I
Exhaust Retaining
Springs
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
60
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MAINTENANCE
Periodic Maintenance Interval Table
See
Page
Frequency
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
Brakes
Hose Routing
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Hose Condition
Fluid Leaks
--
Brake Pads
Brake Disc
77
--
Parking Brakes
Brake System
Brake fluid
45
43, 77
79
R
Fuel Management
Pilot Air Screws
Carburetor (synchronize)
Idle RPM
--
54
--
I
I
I
I
I
I
I
I
I
Throttle Lever
Throttle Cable
Choke Cable
Vent Lines
43
65
65
--
I
I
L
L
I
I
I
I
I
L
L
I
L
L
I
Throttle Position Sensor
Choke
--
I
I
I
65
70
70
--
I
I
I
Fuel Filter
R
I
R
I
Fuel Lines
I
I
I
I
I
I
Air Box
I
I
Drain and Water Traps
NA
Electrical
Auxiliary Shut-Off Switch
Taillight
47
47
47
47
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Brakelight
Headlight
61
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MAINTENANCE
Periodic Maintenance Interval Table
Frequency
See
Page
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
Chassis
Ski Toe Alignment
--
--
I
I
I
I
I
I
I
I
I
I
I
I
Suspension
Mounting Bolts
I
I
I
I
C
I
Steering Fasteners
--
--
Rear Suspension
Fasteners
Suspension Shock Oil
Cooling Fins and Shroud
Skags (Wear Bars)
Ski Saddle/Spindle Bolts
Ski Pivots
--
I
I
I
I
I
I
I
I
--
39
63
64
64
64
63
63
I
I
I
I
I
I
I
I
I
I
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
I
Ski Spindle
I
Steering Post U-Joint
Steering Arm(s)
L
I
Upper / Lower Steering
Post Support Bracket
L
L
L
L
I
Drive Chain Tension
Hood Straps
76
46
89
88
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts
Idler Bolt Jam Nut
Camber Alignment
Radius Rod Bushings
Handlebar Centering
Tether Switch and Strap
Track Alignment
--
I
I
I
I
I
I
I
I
I
--
47
89
88
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Track Tension
Front Limiter Strap
Slider Condition
94
66
N/A
Chaincase Oil
I
I
I
I
I
I
R
R
Gearcase Oil
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
62
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MAINTENANCE
Lubrication
Lack of lubrication will adversely affect your ride and the life of
components. Lubricate with Polaris Premium All Season Grease at 500
miles (800 km) initially, every 1000 miles (1600 km) after that, and
before off-season storage each year. A grease gun kit, complete with
grease and adaptors, is available to lubricate all fittings on Polaris
snowmobiles. See page 99 for the part numbers of Polaris products.
For more information about suspension lubrication and adjustments,
see your Polaris dealer.
NOTE: Lubrication points are indicated by a L in the following
illustrations.
Rear Suspension
63
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MAINTENANCE
Lubrication
Front Suspension
Two components of the IQ front suspension and steering require
lubrication.
S Grease the left and right spindles. Raise the front end of the ma-
chine to permit better grease entry into the spindle area.
S Lubricate the steering post U-joint.
64
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MAINTENANCE
Lubrication
Throttle Cable
Lubricate the throttle cable (1) lightly
with grease or oil. With the engine off,
turn the handlebars to the left and
lubricate liberally as shown.
1
Choke and Cable
Lubricate the choke slide (2) and cables
lightly with oil or grease. Before
turning the engine off, operate the choke
intermittently to draw moisture out of
the choke plunger area and reduce the
possibility of the choke becoming
frozen.
2
65
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MAINTENANCE
Lubrication
n Chaincase Oil Level
It’s the operator’s responsibility to check and maintain the proper
chaincase oil level.
To check the oil level, place the machine on a level surface. The oil
level should be between the “safe” marks on the dipstick (A). Add
Polaris synthetic chaincase oil through the dipstick opening. Do not
overfill. See page 99 for the part numbers of Polaris products.
Flush the chaincase after the first 500 miles, then every 1000 miles or
seasonally. Clean the magnetic plug (B) whenever checking or
changing lubricant.
A
B
CAUTION
Mixing brands or using non-recommended lubricants could result
in excessive wear to internal components. Always use
Polaris-recommended products for your vehicle.
66
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MAINTENANCE
Spark Plugs
A spark plug with a heat range too high will cause engine damage. A
spark plug with a heat range too low will cause excessive fouling and
engine malfunctioning.
In selecting a spark plug heat range for production, a manufacturer
assumes that the engine will be operated under extreme heavy duty
conditions and selects a spark plug that will protect the engine from
internal damage if the purchaser actually does operate the engine in this
manner. This selection could cause the customer who normally
operates the engine under medium or light duty to have spark plug
failure. Refer to your Owner’s Manual Supplement for the specific
spark plug to be used in your machine.
CAUTION
A spark plug with a heat range too high will always cause engine
damage if the engine is operated in conditions more severe than
intended for that plug. Always use the spark plugs recommended
for your snowmobile. See your Owner’s Manual Supplement.
A new engine can cause temporary spark plug fouling due to the
preservative added during the assembly process. Avoid prolonged idle
speeds, which cause plug fouling and carbonization.
S Use recommended spark plugs with the proper gap. Refer to your
Owner’s Manual Supplement for specific information.
S Spark plug torque is 18-22 ft. lbs. (24-30 Nm).
S Always carry spare spark plugs in case of an emergency.
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
67
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MAINTENANCE
Spark Plugs
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
NOTE: Incorrect fuel mixture can often cause a spark plug to appear
too dark or too light in color. Before changing spark plug
heat ranges, be sure the correct main jet is installed in the
carburetor(s). Refer to the Owner’s Manual Supplement or
see your dealer.
1. Normal
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect carburetion adjustments.
2. Wet Fouled
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 injection oil, improper use of the choke, or
incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in
the tool pouch, rotate the spark plug
counterclockwise to remove.
3. Reverse the procedure for spark plug
1
installation.
4. Torque to 18-22 ft. lbs. (24-30 Nm).
5. Install spark plug cap.
68
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MAINTENANCE
Intake Filter
The intake foam filters limit snow ingestion into the intake system.
When operating in loose powder snow, check the top of the foam filters
periodically to remove any accumulation of snow.
CAUTION
Operating the snowmobile with the intake filters removed may
cause carburetor icing. The result will be poor fuel economy or
carburetor malfunction. Always reinstall the intake filters before
operating the snowmobile.
69
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MAINTENANCE
Variable Exhaust System (VES)
Maintenance of the VES is limited to a periodic inspection and
cleaning of system components. Every 1000 to 2000 miles (800-1600
km), bring the machine to an authorized Polaris dealer to have the VES
disassembled, inspected, and cleaned.
NOTE: To ensure maximum performance and minimize required
maintenance, follow the oil recommendations on page 49.
The use of other lubricants may cause improper function of
the valve mechanism and increase the frequency of required
cleaning due to excessive build-up of carbon deposits.
Fuel Filter/Fuel Lines
Inspect the in-tank fuel filter (1) and fuel
lines regularly. Give special attention to the
system’s fuel line condition after periods of
storage. Normal deterioration from weather
and fuel compounds may occur.
1
CAUTION
Kinking the fuel lines or using a pliers or similar tools to remove
fuel lines may cause damage to the lines. If a fuel line has been
damaged or kinked, replace it promptly.
70
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MAINTENANCE
Carburetor
The number stamped in the end of the main jet indicates the jet size.
The jet installed at the time of manufacture is not necessarily correct
for your elevation. It’s your dealer’s responsibility to make sure the
correct main jet is installed.
CAUTION
Operating the snowmobile with incorrect jetting can result in
serious engine damage. Have your Polaris dealer perform all
carburetor adjustments to ensure all adjustments are done
correctly.
Carburetor Adjustments
The frequency at which the carburetors are synchronized or balanced is
important. Properly adjusted carburetors can greatly improve engine
performance, fuel economy, engine life, and reliability.
If you notice any of the following conditions, the carburetor may need
adjustment:
S Hard starting
S Poor idle
S Overheated pistons and cylinder walls
S Plug fouling
S Poor engine response to various throttle valve openings
71
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MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at approximately 1000
miles (1600 km). To inspect, allow the engine and exhaust system to
cool completely. Open the hood and inspect the muffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.
WARNING
Hot exhaust system parts can cause serious burns. Allow
adequate time for the exhaust system to cool. Never perform this
procedure with the engine running.
Engine Cooling
The cooling system on liquid cooled models consists of the following
major components:
S Coolant bottle
S Water pump
S Cylinders
S Heads
S Inlet and outlet manifolds
S Pressure cap
S Heat exchangers
72
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MAINTENANCE
Engine Cooling
Coolant Mixture
The coolant supplied in the system is a 50/50 mixture of
ethylene-glycol and distilled water. This mixture provides protection
against freezing at temperatures to -34° F (-37° C). If greater
protection is required, the percentage of antifreeze to water may be
increased. Use Premium 60/40 anti-freeze coolant, which is already
premixed and ready to use. Do not dilute with water. Never exceed a
60% antifreeze/40% water mixture. Contact you dealer if greater
protection is required.
NOTE: Never add tap water to the cooling system. Minerals cause
deposits and may react adversely with the metals in the
engine and cooling system.
Coolant High Temperature Indicator Light
The high temperature indicator light is controlled by a switch in the
engine cooling system on liquid cooled models. If the engine coolant
reaches a certain temperature, the switch completes a circuit that turns
the light on. If you must drive your machine after the high temperature
indicator light has come on, drive slowly and stop frequently to allow
the engine to cool down. See your dealer.
n Coolant Level
Maintain the coolant level at the “full cold” line on the coolant bottle
when the engine is cold.
CAUTION
Operating the snowmobile with insufficient coolant will result in
overheating and serious engine damage. Always maintain the
coolant level as recommended.
The engine coolant level is controlled by the recovery system. The
recovery system components are:
S Coolant bottle or overflow tank
S Engine filler neck
S Pressure cap (on some models)
S Connecting hoses
73
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MAINTENANCE
Engine Cooling
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine,
the system should be completely drained every two years and a fresh
50/50 or 60/40 mixture of antifreeze and distilled water should be
added. This service must be done when the engine is cold. Ask your
Polaris dealer to check the coolant when he performs the fall tune-up
on your snowmobile.
WARNING
Steam and hot liquids will cause serious burns to your skin.
Never bleed the cooling system or remove the pressure cap when
the engine is warm or hot.
If the pressure cap needs replacement, contact your dealer for the
correct part. Use of a non-standard pressure cap will not allow the
recovery system to function properly.
Bleeding the Cooling System
CAUTION
If coolant flow becomes restricted or plugged, coolant loss, air
lock or engine damage may result. Most cooling systems are
equipped with a filter that should be periodically inspected or
replaced.
If coolant becomes low in the tank, bleed the system of trapped air
using the following procedure:
1. Allow the system to cool completely, then loosen the bleed screw
and fill the reservoir to the FULL COLD mark. Tighten the screw.
2. Apply the parking brake and run the engine at idle RPM until the
thermostat opens (5 to 8 minutes) and stays open.
NOTE: As the thermostat draws in cold coolant from the heat
exchangers, the cold coolant may close the thermostat.
Make sure it opens and stays open.
74
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MAINTENANCE
Engine Cooling
Bleeding the Cooling System
3. Tip the snowmobile slightly onto its right side. Cycle the RPM
from idle to enough RPM (4000) to get coolant to flow, but not
enough to engage the clutch. This allows air to bleed from the rear
crossover tube.
NOTE: There must be enough coolant flow to purge the air from the
crossover hose or rear cooler so you can observe this air
reaching the bottle.
4. Tilt the machine slightly onto its left side so that the coolant bottle
is the highest point in the cooling system. Cycle the RPM as
outlined in step 3.
NOTE: There must be enough coolant flow to purge the air from the
front close-off cooler so you can observe the air reaching the
bottle.
5. Return the snowmobile to its upright position and loosen the bleed
screw at the top of the water outlet manifold. When all trapped air
has been purged, tighten the screw.
6. Turn off the engine and release the parking brake. Allow the
system to cool completely.
NOTE: After cool-down, three (3) or more ounces of coolant may
have to be added.
7. Remove the pressure cap and check the coolant level. Add coolant
to the fill line if necessary.
75
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MAINTENANCE
Drive Chain Tension
To obtain correct chain tension:
1. Rotate the driven clutch
counterclockwise to move all
chain slack to the tensioner
side. Lock the brake lever
lock, or have an assistant hold
the brake lever firmly.
B
2. Loosen the adjuster bolt jam
nut (A).
A
3. Finger tighten the adjuster
bolt (B) until it can no longer
be adjusted by hand, then
back off 1/4 turn.
4. Tighten the jam nut while
holding the adjuster bolt.
5. The chain is now tensioned. Release the brake lever lock.
76
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MAINTENANCE
n Hydraulic Brake Inspection
Frequently inspect the
brake lever reserve.
Squeeze the brake lever.
It should move no closer
to the handgrip than 1/2″
(1.3 cm). A smaller
1/2″ (1.3 cm)
distance indicates low
brake fluid level or air in
the hydraulic system.
Refer to the brake bleeding
information on page 80.
Brake pads must be replaced when the brake pad material becomes
thinner than the backing plate (approximately 1/16″/1.6 mm). A kit is
available for replacing brake pads. See your dealer.
WARNING
Brake failure during operation can result in serious injury or
death. Properly functioning brakes are vital to your safety. Be
sure the brake pads do not drag on the disc and that brake lever
travel is not excessive.
Always replace brake pads when the brake pad material
becomes thinner than the backing plate (approximately 1/16″/1.6
mm).
77
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MAINTENANCE
Brakes
Brake Components
4
2
1. Brake Caliper
2. Chaincase
3. Brake Disc
4. Backing Plate
5. Brake Pad Material (Replace when thickness is less than 1/16″).
Excessive Brake Lever Travel
Hydraulic brakes are self-adjusting, but if excessive brake pad
clearance develops, as described on page 77, the machine should be
returned to an authorized Polaris dealer for inspection and adjustment.
78
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MAINTENANCE
Brakes
Brake Fluid
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury.
WARNING
Keep the master cylinder cover free of dirt and debris. The vent
slits allow for diaphragm movement, and if they become plugged,
movement of brake fluid below the diaphragm may be restricted,
altering brake function.
CAUTION
Brake fluid will damage decals, paint and some plastics. Always
wipe up spills immediately.
Maintain the brake fluid level between the MIN and MAX marks on
the master cylinder reservoir. Use only Polaris DOT 4 high temperature
brake fluid. See page 99 for the part numbers of Polaris products.
79
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MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING
Operating the vehicle with a spongy brake lever can result in loss
of brakes, which could cause an accident and lead to serious
injury or death. Never operate the vehicle with a spongy-feeling
brake lever.
During the bleeding procedure, keep the brake handle as level as
possible. The reservoir must be in this position to minimize the
possibility of air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks. Reinstall the gasket and cover.
3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder
valve 3/4 of a turn to release air.
5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.
WARNING
Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or
death. Always add brake fluid to the fill line as recommended.
7. After bleeding is complete, refill the reservoir to the proper level.
See page 79.
8. Reinstall the gasket and cover.
80
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MAINTENANCE
Headlights
Headlight Adjustment
25’ (7.6 m)
x
x
2″ (5.1 cm)
The headlight may be adjusted for vertical aim using the following
procedure:
1. Place the snowmobile on a level surface with the headlight
approximately 25 feet (7.6m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall.
3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed 2″ (5.1 cm) below the mark placed on the
wall in step 2.
NOTE: Rider weight must be included on the seat.
5. Turn the adjustment nut (1),
located inside the hood,
just below the headlamp
opening. Turn the knob in or
out as needed for proper aim.
1
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MAINTENANCE
Headlights
NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin
leaves a residue, causing a hot spot that will shorten the life
of the lamp.
Removing Halogen Bulbs - High/Low Beam
1. Pinch the ends of the spring (1)
together and lift until it releases
2
from the spring retainer.
2. Lift spring carefully around
wire harness (2) and flip to
outside of housing.
3
3. With the wire harness attached
to the bulb (3), withdraw bulb
from housing.
1
4. Grasp bulb by metal base and carefully separate bulb from
harness.
Installing the Bulb
1. Hold bulb by metal base and install into wire harness.
2. Insert bulb into housing.
3. Carefully flip spring back into housing placing it around wire
harness.
4. Squeeze spring together until it is over the spring retainer and
release.
5. Verify headlight aim.
82
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MAINTENANCE
Clutch System
WARNING
If you become aware of higher than normal clutch engagement or
an unusual vibration or shift pattern, see your dealer immediately.
Do not operate the machine until repairs have been made.
All clutch maintenance and repairs must be performed by an
authorized Polaris dealer. Any unauthorized modifications to
clutches, such as adding or removing weights, will void the
warranty.
CAUTION
The bushings in the weights and rollers of Polaris clutches are
made of a material that may be damaged if lubricated. Do not
lubricate clutch bushings.
Periodically inspect the clutch sheaves for damage, wear, or belt
residue. To maintain optimum performance, clean with non-oil based
cleaners such as isopropyl alcohol.
Clutch Alignment and Offset
Clutch center distance and alignment (A) are
crucial to maintaining optimum performance.
The drive belt is a very important part of the drive
system. Belt width and length must match the
center distance of the clutches and sheave width of
A
the drive clutch. For this reason, Polaris
recommends that only O.E.M. belts be used.
Other belts may match the dimensions, but can
drastically change the shift pattern, resulting in
poor performance. See your dealer for service and
adjustments.
NOTE: A worn belt will continue to function, but
will not deliver maximum performance.
Always carry a spare belt in case of an
emergency.
83
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MAINTENANCE
Clutch System
n Drive Belt Condition
Periodically check the condition and tension of the drive belt, and
always carry a spare belt. For improved drive-away during extremely
cold temperatures, remove the belt and warm it to room temperature.
Reinstall it before starting the snowmobile.
Drive Belt Removal
1. Stop the engine. Apply the brake (or lock the parking brake if
equipped).
2. Open the hood, remove the clutch guard retaining pin and open the
clutch guard.
3. Locate the L-wrench in the tool kit and install it into the open
threaded hole in the outer sheave of the clutch. Rotate the wrench
until the sheaves open far enough to remove the belt.
Drive Belt Installation
1. Drop the drive belt over the
A
drive clutch and pull back the
slack (A).
NOTE: To ensure satisfactory belt
life, install belts so they
operate in the same
direction of rotation by
positioning the
identification numbers so
that you can read them. If
required, separate the
sheaves as outlined in the
belt removal procedures.
B
2. Rotate the L-wrench to tighten
the sheaves. Remove the
wrench and store in the tool kit.
3. Close the clutch guard and
reinstall the retaining pin.
4. Close and secure the hood and
release the parking brake.
84
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MAINTENANCE
Clutch System
n Drive Belt Deflection
A
B
C
Measure belt deflection with both
clutches at rest and in their full
neutral position.
Place a straight edge on the belt (A)
and apply downward pressure while
measuring at point B. This
measurement should be 1 1/4”.
Drive Belt Adjustment
1. Loosen the 7/6” jam nut on the belt width adjuster.
2. Using a 1/8” Allen wrench, adjust the threaded set screw (C) as
needed.
NOTE: Turn the set screw in (clockwise) to increase the distance
between the sheaves and out (counterclockwise) to decrease
the distance.
3. Tighten the jam nut.
Clutch Center Distance
See your Owner’s Manual Supplement for recommended center
distance for your machine. If adjustment is necessary, see your dealer.
Due to tolerances in belt length, it may be necessary for your dealer to
make minor adjustments in the driven clutch to achieve correct belt
tension.
85
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MAINTENANCE
Torque Stop
If your snowmobile is equipped
with an engine torque stop (1),
periodically check torque stop
clearance. With clutches in
proper alignment, the torque stop
clearance should be a minimum
of .010″ to a maximum of .030″
from the engine case (2). Adjust
if necessary, and lock the jam
nut.
2
1
Reverse Kit Maintenance
If your snowmobile is equipped with reverse, or if you have a reverse
kit installed, it’s especially important to maintain track tension as
specified on page 88.
WARNING
Improper track tension can cause serious damage to the
snowmobile, which can result in loss of vehicle control and
serious injury or death. Always maintain the track tension as
specified.
Allow the engine to reach idle speed before attempting to shift into or
out of reverse.
CAUTION
Damage will occur to chaincase or transmission if shifting is
attempted before the machine has come to a complete stop.
Make sure the snowmobile has completely stopped and the
engine has returned to idle speed before shifting gears.
86
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MAINTENANCE
Chain Tension
Maintain the proper chain tension as outlined on page 76.
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
Polaris dealer. His experienced and trained service technician will keep
your machine in peak operating condition.
Tool Kit
A tool kit is included with each machine for emergency and routine
maintenance. Always keep the tool kit with the snowmobile.
NOTE: The tools and maintenance items mentioned in this book, as
well as a long line of other Polaris accessories, are available
at your Polaris dealer.
87
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MAINTENANCE
Track Maintenance
WARNING
Moving parts can cut and crush body parts. When performing the
checks and adjustments recommended on the following pages,
stay clear of all moving parts. Never perform track measurement
or adjustments with the engine running.
Track Tension
Track adjustment is critical for proper handling. Always maintain
correct tension and alignment.
Tension adjustments should be made only after the track is warmed up
and limber.
1. Turn the machine off.
2. Lift the rear of the machine and safely support it off the ground.
3. Place the recommended weight or downward pressure on the track
at the specified distance (see Track Tension Data below) ahead of
the center of the rear idler wheel.
NOTE: Measure at the point where the weight is hanging.
4. Check for specified slack between the wear surface of the track clip
and the plastic slider (C).
If the track needs adjustment:
Slider
5. Loosen rear idler shaft bolt (D).
6. Loosen locknuts (A).
7. Tighten or loosen the
track adjusting screws (B)
as necessary to provide
equal adjustment on both
sides of the track.
B
A
D
weight
C
Track
Track Tension Data
Model
Weight
Measurement
Location
Measurement
440 IQ
10 lbs. (4.54 kg)
16″ ahead of rear
1 1/4 - 1 1/2”
(3.2 - 3.8 cm)
idler shaft
88
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MAINTENANCE
Track Maintenance
If the track needs adjustment (continued):
8. Repeat measurement on the other side of the track.
NOTE: Check more frequently when machine is new.
9. Start the machine and slowly rotate the track at least five
revolutions. Let the track come to a stop (do not apply brakes).
10. Check track alignment (see page 89) and adjust as necessary.
11. Tighten locknuts (A).
12. Tighten idler shaft bolts (D) and torque to 35 ft. lbs. (47.5 Nm).
n Track Alignment
Periodically check that the track is
centered and running evenly on the
slide rails. Misalignment will cause
excessive wear to the track and slide
rail.
1. Safely support the rear of the
machine with the track off the
ground.
2. Start the engine and apply a small
amount of throttle until the track
turns slowly at least five complete
revolutions. Stop the engine and
let the track come to a stop (do not
apply brakes).
A
3. Inspect track alignment by looking
through the track window to make
sure the rails (A) are evenly
spaced on each side. If the track runs to the left, loosen left
locknut and tighten the left adjusting bolt. If the track runs to the
right, loosen right locknut and tighten the right adjusting bolt.
4. After adjustments are complete, tighten locknuts and torque idler
shaft bolts to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
89
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MAINTENANCE
Track Maintenance
Track Inspection
WARNING
Broken track rods are a serious safety hazard. They can cause a
rotating track to come off the machine, which could cause serious
injury or death. Never operate with a damaged track. Never
rotate a damaged track under power.
2
Using a hoist, safely lift and support the
rear of the snowmobile off the ground.
Rotate the track by hand to check for
possible damage.
3
2
1
1
Carefully examine the track along the
entire length of each rod, bending the
track and inspecting for breakage. The
three most common damage areas are
shown in the illustration.
Replace the track if any rod damage is
found.
Track Lubrication
WARNING
Operating with insufficient lubrication between the slider and track
guide clips can cause track failure, loss of vehicle control and loss
of braking ability, which can result in serious injury or death.
Avoid operating for extended periods on ice and other surfaces
that have little or no snow for lubrication.
The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new slider can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.
NOTE: If excessive slider wear occurs due to poor snow conditions,
additional wheel kits are available. See your dealer for more
information.
NOTE: Track damage or failure caused by operation on ice or under
other poor lubrication conditions will void the track warranty.
90
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MAINTENANCE
Steering System
Steering Inspection and Adjustment
Each week, or before a long ride, check all fasteners and tighten if
necessary. Specifically check fasteners marked with a +.
91
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MAINTENANCE
Steering System
Ski Alignment
WARNING
Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Do not attempt to
change the ski alignment or camber adjustment. See your
Polaris dealer.
With the handlebars in a straight ahead position, and with vehicle
weight compressing the suspension, measure from the straight edge of
the skis at the center of the ski mounting bolt. The measurement
between the skis at point X should be 1/8″ to 1/4″ greater than the
measurement at point Y.
NOTE: If the skis are misaligned, we recommend that your dealer
correct the alignment, since camber adjustment may also be
affected.
92
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MAINTENANCE
Steering System
n Ski Skags
WARNING
Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death.
See your dealer’s studding chart for recommended skags. If you
install longer or more aggressive carbide skags than the original
equipment, it may also be necessary to add track studs to
maintain proper vehicle control while turning on hard-packed
snow or ice.
Check skags weekly to maintain positive steering characteristics. Skags
must be replaced when worn to half their original diameter.
NOTE: Carbide skags must be replaced if any abnormal wear or
chipping is found.
Skag Replacement
1. Raise and support the front of the
machine so the skis are
approximately 6″ (15.2 cm) from
the ground.
2. Remove the attaching hardware
and pry the skag (A) downward.
3. Remove the forward portion of
the skag.
Reverse this procedure for new skag
installation.
93
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MAINTENANCE
Suspension Maintenance
n Slider Wear
Measure slider thickness at
several points along the
rail. Have your dealer
7/16″
(1.1 cm)
replace the slider when it’s
worn down to the top of
the wear groove (A). Do
not operate the snowmobile if
slider thickness measures less
than 7/16″ (1.1 cm).
A
n Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your snowmobile’s reliability and
cause needless repairs and down time. Before beginning any
snowmobile trip, a visual inspection will uncover potential problems.
Check the following items on a weekly basis or before any long trip:
n Check rear idler wheel bolts for tightness.
n Check rear idler adjusting bolt locknuts for tightness. See page 89
for torque specs.
n Check front torque arm limiter strap condition.
n Check slider condition - have your dealer replace when worn to
minimum thickness.
n Check track tension (beginning on page 88).
n Lubricate/grease all suspension components (see page 63).
n Check ski runner/skag condition.
94
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MAINTENANCE
Extended Storage
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood,
chassis, and plastic parts. Wipe down remaining surfaces with a damp
cloth. Clean and touch up with paint any rusted or previously painted
surfaces. Be sure that corrosive salt and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors
(grease, oil or paint).
The machine should be stored in a dry garage or shed, out of direct
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
Controls and Linkage
All bushings, spindle shafts, tie rod ends, and cables should receive a
light coat of oil or grease.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Lubricate the
sheave faces of the drive and driven clutches with a light coat of oil or
Polaris Cable Lubricant. See page 99 for part numbers. Do not
lubricate clutch components, except the driven clutch shaft bushing as
outlined in the Master Repair Manual. See your dealer.
95
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MAINTENANCE
Extended Storage
Engine and Carburetor Protection
Proper preparation of the engine and fuel system is vital to the
prevention of rust and corrosion on precision engine parts during
storage. Whenever the machine is stored for a period of more than 60
days,the engine must be fogged with fogging oil. Follow the engine
fogging instructions provided on the can. See page 99.
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to
the fuel tank. See page 99 for the part numbers of Polaris products.
Follow the instructions on the can, running the engine for five minutes
to get additives through the entire fuel system. Top off with fresh
premixed fuel.
Using a fuel stabilizer and topping off the fuel tank eliminates the need
to drain the fuel system. If you prefer to drain the fuel tank, use the
following procedure.
1. Transfer unused fuel from the fuel tank to an approved fuel
container using a siphon pump. Do not re-use fuel after storage.
2. Securely support the front of the snowmobile with a jack stand so
the machine is elevated and the engine is tilted rearward.
3. Remove the spark plug(s).
4. Rotate the engine slowly, watching the piston until it’s at bottom
dead center (BDC), the lowest position in the cylinder. On twin
cylinder models, the opposite piston will be up.
5. Pour approximately two ounces of Polaris injection oil into the
spark plug hole.
6. Wait one to two minutes and perform steps 3 to 5 on remaining
cylinders.
7. Replace the spark plugs and lower the machine to the floor.
96
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MAINTENANCE
Extended Storage
Electrical Connections
Separate electrical connector blocks and clean corrosive build-up from
connectors. Lubricate or pack connector blocks with dielectric grease
and re-connect. See page 99 for the part numbers of Polaris products.
Replace worn or frayed electrical wire and connectors. Be sure wiring
harness is properly secured away from sharp edges, steering linkage,
moving parts, and hot exhaust parts.
Track and Suspension
Moderate track tension should be
maintained during summer storage.
The machine should be supported off
the ground to allow the track to hang
freely.
97
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MAINTENANCE
Transporting the Snowmobile
Whenever the snowmobile is transported:
2
1. Turn the fuel valve
clockwise to OFF to shut
off the fuel supply (1).
Turn the valve
1
counter-clockwise to
ON to turn the fuel
supply on (2).
NOTE: The fuel valve is
located under the
hood.
2. Be sure the fuel cap is installed correctly.
3. Always tie the snowmobile to the transporting unit securely
using suitable straps.
98
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POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
2870791
2873023
Fogging Oil (12 oz. Aerosol)
Synthetic 2-Cycle Racing Oil (gal.)
Chaincase Lubricants
2873105
2872951
Synthetic Chaincase Lubricant (qt.)
Synthetic Chaincase Lubricant (12 oz.)
Grease / Specialized Lubricants
2871312
2871322
2871423
2871329
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)
Coolant
2871323
2871534
Anitfreeze, 60/40 Premix (gal.)
Anitfreeze, 60/40 Premix (qt.)
Additives / Miscellaneous
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT 4 Brake Fluid (12 oz.)
Engine Degreaser (12 oz.)
Isopropyl
2871326
2870652
2872189
2872893
2870505
2872889
2872890
Brake and Clutch Cleaner
Carb and Throttle Body Cleaner
99
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TROUBLESHOOTING
Engine Troubleshooting
CAUTION: Unless you have experience and training in two-cycle
engine repair, see your dealer if technical problems arise.
Problem
Probable Cause
Solution
Erratic engine
operating RPM
during accelera-
tion or load
Drive clutch binding -Disassemble drive clutch to inspect shift
weights for wear and free operation.
SEE YOUR DEALER.
-Clean and polish stationary shaft hub.
Driven clutch
variations
malfunction
-Replace ramp buttons and rollers.
SEE YOUR DEALER.
-Inspect movable sheaves for excessive
bushing clearance and replace if necessary.
SEE YOUR DEALER.
-Replace drive belt.
Harsh drive
clutch
Drive belt worn or
too narrow
engagement
Excessive belt/sheave -SEE YOUR DEALER.
clearance
Drive belt turns Wrong belt for
application
-Replace drive belt.
over
Clutch alignment out -Adjust alignment offset.
of spec
Engine mount broken -Inspect and adjust or replace.
or loose
SEE YOUR DEALER.
Machine fails to Clutch jammed
move
-Belt twisted, spring broken, weights stuck,
lubricated. SEE YOUR DEALER.
Track jammed
-Foreign object caught or slider melted to
track clips due to lack of lubrication.
-Machine may be frozen to ground. Track
may be iced up.
Chaincase sprocket or -Chain is loose or broken, chain tightener is
chain jammed or bro- loose. SEE YOUR DEALER.
ken
100
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause
Solution
Noise in drive
system
Broken drive clutch
components
-SEE YOUR DEALER.
Bearing failure/
-SEE YOUR DEALER.
chaincase, jackshaft,
or front drive shaft
Drive belt surface flat
spots
-Inspect and replace if necessary.
-Inspect and adjust or replace.
-Inspect and replace if necessary.
Drive chain loose or
worn, sprocket teeth
broken
Poor low RPM Worn drive belt
performance
Excessive belt/sheave -SEE YOUR DEALER.
clearance
Loose torque stop
Sticky clutch
Seized engine
-Inspect and adjust.
-SEE YOUR DEALER.
Engine doesn’t
turn
-SEE YOUR DEALER. Seizure is a result
of poor lubrication, inadequate fuel supply,
broken parts, or improper cooling.
Hydrostatic lock
-Fuel may have entered crankcase while
vehicle was standing or being transported.
SEE YOUR DEALER to correct cause.
Drain plug(s) are located on lower crank-
case for emergency draining.
Engine requires Poor gasoline or not
more than enough fuel getting to
-Replace with fresh winter fuel.
normal pulls to engine
start
101
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause
Solution
Engine turns
but fails to start
Faulty ignition
-Remove spark plug(s) and replace with
new plug(s). If engine still fails to start,
check for spark; if no spark SEE YOUR
DEALER.
No fuel to engine
-Make sure the fuel valve is “ON”. Check
tank level and fill up with correct fuel.
-Ice in fuel line, filter, or pump. On the
standard Polaris carburetor, the choke will
not function with the throttle depressed.
See second item under “Probable Cause” of
“Engine continually backfires”.
Flooded engine (nor-
mal situation caused
by too much chok-
ing)
-Hold throttle open, crank engine several
times (may be necessary to change plug(s),
however, the plug(s) may operate satisfac-
torily when dried).
Poor engine compres-
sion
-Running too lean a mixture (too small a
main jet will cause seizure resulting in loss
of power). SEE YOUR DEALER. This
indicates a major engine problem that must
be repaired before engine is run.
Engine lacks
power
Fouled or defective
spark plug
-Change and test operation.
Fuel filter (loss of
high RPM power)
-Check fuel filter flow. Disconnect hose
and drain about 1/2 cup. Fuel flow should
be steady and encompass the entire diame-
ter of fuel line. If not, replace filter.
Incorrect clutching
-SEE YOUR DEALER.
Carburetor and fuel
pump
-There’s no adjustment to change power
output. SEE YOUR DEALER.
Engine
continually
backfires
Faulty plug(s)
Carburetor
-Change plug(s)
-Dirt or ice in fuel system. (Deicer should
be added to non-ethanol fuel at all times for
assurance against fuel line icing.)
102
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TROUBLESHOOTING
Suspension Troubleshooting
Problem
Solution (perform only one change at a time)
Rear suspension
-Increase torsion spring preload
-Increase rear shock compression damping by turning screw
bottoms too easily
clockwise
-Increase torsion spring wire diameter (see your dealer)
Rides too stiff in
rear
-Check for binding suspension shafts and grease all pivot points
-Decrease torsion spring preload adjustments
-Decrease rear shock compression valving by turning screw
counterclockwise (if equipped with optional Indy Select shock)
-Change to lighter valving if (if equipped with Fox™ shocks)
-Check for proper track tension
Machine darts from -Make sure skis are aligned properly
side to side
-Make sure spindles and all steering components are free turning
-Make sure skags are straight on skis
-Check slider and replace if worn
-Reduce ski pressure:
SReduce IFS spring preload
SReduce rear torsion spring preload
Front end pushes
Steering is heavy
-Check for worn skags
-Check for binding suspension shafts and grease all pivot points
-Increase IFS spring preload by adjusting cam or threaded ad-
juster
-Decrease front limiter strap length
-Check ski alignment
-Check skags and skis for damage
-Reduce ski pressure:
SIncrease front track spring preload
SReduce IFS spring preload by adjusting cam
SReduce rear torsion spring preload
Setting up for deep -Change worn slider
snow operation -Move front track shock assembly to upper position
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TROUBLESHOOTING
Belt Troubleshooting
Belt Wear/Burn
Belt Wear/Burn Diagnosis
Causes
Solutions
Driving at low RPM
Drive at higher RPMs. Gear the machine down. Check belt
deflection.
Insufficient warm-up
Towing at low RPM
Warm the engine at least five minutes. Take the drive belt off
the machine in extremely cold weather and warm it up.
Break machine loose from the snow.
Do not tow in deep snow. Use fast, aggressive throttle to
engage clutch.
Riding with high RPM Lower the gear ratio. Remove windage plates from the
and slow speed (8000
clutch. Reduce RPM. Avoid riding in high ambient
RPM/10 MPH)
temperatures.
Ice and snow build-up
between track and
tunnel
Warm the engine at least five minutes. Take the drive belt off
the machine in extremely cold weather and warm it up.
Break machine loose from the snow.
Poor engine
performance
Check for carb and choke synchronization, fouled plugs,
debris in the carbs, and water, ice, or dirt in gas tank or fuel
line.
Loading machines onto Skis may gouge into trailers and prevent the drivetrain from
trailers
spinning properly. Use enough speed to drive the machine
completely onto the trailer. Push and pull it to finish
loading if necessary.
Clutch malfunction
Inspect clutch components. See your dealer.
Use fast, aggressive throttle to engage clutch.
Slow, easy clutch en-
gagement
104
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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 contained in this manual. Contact your Polaris dealer for
replacement parts, service or warranty. Your dealer receives frequent
updates on changes, modifications and tips on snowmobile
maintenance, which may supersede information contained in this
manual. Your dealer is also familiar with Polaris policies and
procedures and will be happy to assist you.
When contacting us about parts, service, or warranty, always provide
the following information:
1. Serial number 5. Details of trouble experienced
2. Model number 6. Length of time and conditions of operation
3. Dealer name
7. Previous correspondence
4. Date of purchase
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
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 offi-
cials, the owner must call Polaris Customer Service.
B. Owners must provide their name, address, telephone num-
ber 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.
105
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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 transferrable 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 purposes other
than for which it was manufactured. The warranty does not cover any damages that oc-
cur 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 punc-
turing of upholstery material, corrosion or defects in parts, components or the snowmo-
bile 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, NEG-
LIGENCE, 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.
106
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-
LAR 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
recommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
107
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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 re-
quired 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
Tracks
Ski wear rods
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
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Fuel
Sealants
Hotel fees
Towing charges
Mileage
Meals
Shipping/ handling fees
Product pick-up/delivery
Rentals/Loss of product use Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper en-
gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or
contamination; operator error or abuse; improper component alignment, tension, adjust-
ment or altitude compensation; failure due to snow, water, dirt or other foreign substance
ingestion/contamination; improper maintenance; modified components; use of aftermar-
ket 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 dam-
aged by abuse, accident, fire or any other casualty not determined a defect of materials or
workmanship.
108
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WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused
snowmobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is
transferable 120 days after the original purchase date, free of charge, through any Polaris
snowmobile dealer. 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
registration form. This form is your proof of warranty.
Consumer Exclusions
S
Each repair visit after the first twelve months of standard warranty coverage is subject
to a $50 deductible.
S
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.
S
Snowmobiles used for commercial purposes or for racing are excluded from cover-
age.
Coverage
Coverage for second year engine failures due to defects in materials and workmanship
will be determined by Polaris in its sole discretion. Coverage is automatic with no
additional paperwork required. The free Second Year Engine Service Contract is subject
to a $50 deductible per visit. Regular, documented service maintenance visits are
required to validate this warranty.
A partial list of items excluded from coverage includes:
S
S
S
S
S
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.
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.
S Failure due to unauthorized service.
S
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.
S
S
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.
S
S
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.
S
S
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 ex-
cluded from coverage.
S
S
Electrical components are excluded from coverage.
Gearcases and transmissions are excluded from coverage.
109
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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.
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 105).
110
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MAINTENANCE RECORD
DATE
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
111
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MAINTENANCE RECORD
DATE
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
112
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MAINTENANCE RECORD
DATE
MILES/KM
TECHNICIAN
SERVICE PERFORMED / COMMENTS
113
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INDEX
A
E
Accessories . . . . . . . . . . . . . . . . . . 38-41
Avalanches . . . . . . . . . . . . . . . . . . . . 13
Electrical Connections . . . . . . . . . . . 97
Emergency Starting . . . . . . . . . . . . . . 57
Emergency Stopping . . . . . . . . . . . . . 56
Engine and Carburetor Protection . . 96
Engine Break-In . . . . . . . . . . . . . . . . 48
B
Before Starting the Engine . . . . . . 43-46
Belt Troubleshooting . . . . . . . . . . . 104
Bleeding the Cooling System . 67, 74-75
Bleeding the Hydraulic Brake System 80
Brake Components . . . . . . . . . . . . . . 78
Brake Fluid . . . . . . . . . . . . . . . . . . . . 79
Brake Lever Travel . . . . . . . . . . . 44, 78
Brake, Park . . . . . . . . . . . . . . . . . . . . 45
Brakes . . . . . . . . . . . . . . . . . . . . . . 78-80
Brakes, Hydraulic . . . . . . . . . . . . . . . 44
Engine Safety . . . . . . . . . . . . . . . . . . .
9
Engine Stop Switch . . . . . . . . . . 47, 56
Engine Troubleshooting . . . . . . 100-102
Engine Warm-Up . . . . . . . . . . . . . 52-53
Excessive Speed . . . . . . . . . . . . . . . . 11
Exhaust System . . . . . . . . . . . . . . . . . 72
F
Fall Tune-Up . . . . . . . . . . . . . . . . . . . 87
Features . . . . . . . . . . . . . . . . . . . . . 24-27
Flushing the Cooling System . . . . . . 74
Front Rear Scissor Stop . . . . . . . . . . . 34
Front Springs . . . . . . . . . . . . . . . . . . 31
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 70
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 70
Fuel Recommendations . . . . . . . . . . . 49
C
Carburetion . . . . . . . . . . . . . . . . . . 54-55
Carburetor . . . . . . . . . . . . . . . . . . . . . 71
Carburetor Adjustments . . . . . . . . . . 71
Chain Tension . . . . . . . . . . . . . . . . . . 87
Chaincase Oil Level . . . . . . . . . . . . . 66
Choke and Cable . . . . . . . . . . . . . . . . 65
Cleaning and Preservation . . . . . . . . . 95
Clutch Alignment . . . . . . . . . . . . . . . 83
Clutch and Drive System . . . . . . . . . 95
Clutch Center Distance . . . . . . . . . . . 85
Clutch Cover Warning . . . . . . . . . . . 20
Clutch System . . . . . . . . . . . . . . . . 83-85
Clutches . . . . . . . . . . . . . . . . . . . . . . 16
Cold Weather Drive-Away . . . . . . . . 16
Controls . . . . . . . . . . . . . . . . . . . . 24-27
Controls and Linkage . . . . . . . . . . . . 95
Coolant Level . . . . . . . . . . . . . . . . . . 73
Coolant Mixture . . . . . . . . . . . . . . . . 73
Cooling . . . . . . . . . . . . . . . . . . . . . 72-75
H
Halogen Bulbs . . . . . . . . . . . . . . . . . 82
Handlebar Adjustments . . . . . . . . . . . 37
Handlebar with Riser Block . . . . . . . 37
Headlight Adjustment . . . . . . . . . . . . 81
Headlights . . . . . . . . . . . . . . . . . . . 81-82
High Temperature Indicator . . . . . . . 73
Hydraulic Brake Inspection . . . . . . . . 77
I
Ice and Snow Build-up . . . . . . . . . . . 14
IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 28
IFS Adjustment Options . . . . . . . . . . 28
IFS Components . . . . . . . . . . . . . . . . 28
Inadequate Snow Conditions . . . . . . 17
Independent Front Suspension . . . . . 28
Intake Filter . . . . . . . . . . . . . . . . . . . . 69
Intake Silencer . . . . . . . . . . . . . . . . . 16
D
Daily Storage . . . . . . . . . . . . . . . . . . 58
Disabled Operators . . . . . . . . . . . . . . 11
DRAGON Ignition System . . . . . . 26-27
Drive Belt . . . . . . . . . . . . . . . . 16, 84-85
Drive Chain Tension . . . . . . . . . . . . . 76
Driver Awareness . . . . . . . . . . . . . . . 12
Driving Downhill . . . . . . . . . . . . . . . 14
Driving in Hilly Terrain . . . . . . . . . . 15
Driving on Slippery Surfaces . . . . . . 14
Driving Responsibly . . . . . . . . . . . . . 18
J
Jetting Guidelines . . . . . . . . . . . . . . . 55
L
Lighting Check . . . . . . . . . . . . . . . . . 47
Lubrication . . . . . . . . . . . . . . . . . . 63-66
114
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INDEX
M
S
Maintenance Interval Table . . . . . . 60-62
Maintenance Program . . . . . . . . . . . . 59
Maintenance Record . . . . . . . . . 111-113
Maneuverability . . . . . . . . . . . . . . . . 16
Steering Inspection . . . . . . . . . . . . . . 91
Steering System . . . . . . . . . . . 46, 91-93
Stopping . . . . . . . . . . . . . . . . . . . . . . 56
Storage . . . . . . . . . . . . . . . . . . 58, 95-97
Survival Preparation . . . . . . . . . . . . . 10
Suspension . . . . . . . . . . . . . . . . . . . . 97
Suspension Coupling . . . . . . . . . . . . 34
Suspension Maintenance . . . . . . . . . . 94
Suspension Performance Tips . . . . . . 32
Suspension Troubleshooting . . . . . . 103
Suspension, Front . . . . . . . . . . . . . 28-31
Suspension, Rear . . . . . . . . . . . . . . 32-36
O
Oil Recommendations . . . . . . . . . . . . 49
Operating Area . . . . . . . . . . . . . . . . . 47
Operation Warning . . . . . . . . . . . . 22-23
Operator Safety . . . . . . . . . . . . . . . . 7-19
P
Passenger Warning . . . . . . . . . . . . . . 21
Polaris Products . . . . . . . . . . . . . . . . 99
Pre-Ride Checklist . . . . . . . . . . . . . . 42
Pre-Ride Inspections . . . . . . . . . . . 42-47
Pre-Ride Suspension Inspection . . . . 94
Pressure Cap Warning . . . . . . . . . . . . 20
Symbols . . . . . . . . . . . . . . . . . . . . . . .
7
T
Tether Switch . . . . . . . . . . . . . . . . . . 47
Throttle Cable . . . . . . . . . . . . . . . . . . 65
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 87
Torque Stop . . . . . . . . . . . . . . . . . . . 86
Torsion Spring Tension . . . . . . . . . . . 33
Towing . . . . . . . . . . . . . . . . . . . . . . . 58
Track . . . . . . . . . . . . . . . . . . . . . . . . . 97
Track Alignment . . . . . . . . . . . . . . . . 89
Track Cooling . . . . . . . . . . . . . . . . . . 52
Track Inspection . . . . . . . . . . . . . 46, 90
Track Lubrication . . . . . . . . . . . . . . . 90
Track Maintenance . . . . . . . . . . . . 88-90
R
Rear Rear Scissor Stop . . . . . . . . . . . 35
Reverse Kit Maintenance . . . . . . . . . 86
Rider Capacity . . . . . . . . . . . . . . . . . 11
Riding Apparel . . . . . . . . . . . . . . . . . 10
Riding Position . . . . . . . . . . . . . . . . . .
9
S
Safety Decals and Locations . . . . . 20-23
Scissor Stop . . . . . . . . . . . . . . . . . 34-35
Second Year Engine Service Contract 109
Service and Warranty Information . . 105
Shock Absorber Components . . . . . . 29
Shock Damping . . . . . . . . . . . . . . . . 30
Shock Spring Preload, Front . . . . . . . 30
Shock Valving . . . . . . . . . . . . . . . . . . 31
Track Safety . . . . . . . . . . . . . . . . . . . .
9
Track Tension . . . . . . . . . . . . . . . . . . 88
Track Tension Data . . . . . . . . . . . . . . 88
Track Warm-Up . . . . . . . . . . . . . . 52-53
Track Warning . . . . . . . . . . . . . . . . . 21
Traction Products . . . . . . . . . . . . . . . 39
Transporting the Snowmobile . . . . . . 98
Troubleshooting . . . . . . . . . . . . 100-104
Signal words . . . . . . . . . . . . . . . . . . . .
7
Skag Replacement . . . . . . . . . . . . . . . 93
Ski Alignment . . . . . . . . . . . . . . . . . . 92
Ski Skags . . . . . . . . . . . . . . . . . . . . . 93
Slide Rail and Track Cooling . . . . . . 52
Slider Wear . . . . . . . . . . . . . . . . . . . . 94
Spark Plugs . . . . . . . . . . . . . . . . . . 67-68
Start the Engine and Check . . . . . . . . 47
Starting, Emergency . . . . . . . . . . . . . 57
Starting a Cold Engine . . . . . . . . . . . 51
Starting a Warm Engine . . . . . . . . . . 51
Starting the Engine . . . . . . . . . . . . . . 51
Steering Adjustment . . . . . . . . . . . . . 91
V
Variable Exhaust System . . . . . . . . . . 70
Vehicle Identification Numbers . . . . . .
6
W
Warning Labels . . . . . . . . . . . . . . . 20-23
Warranty . . . . . . . . . . . . . . . . . . 105-110
Wear Strips . . . . . . . . . . . . . . . . . . . . 41
Weight Transfer During Acceleration 36
Windchill/Temperature Charts . . . . . . 19
115
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