Polaris Offroad Vehicle 550 IQ 136 User Manual

550 IQ Shift

550 IQ 136

550 IQ LXT

Snowmobile Owner's Manual

for Maintenance and Safety

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The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

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For your nearest Polaris dealer,

call 1-800-POLARIS

or visit www.polarisindustries.com

Polaris Sales Inc.,

2100 Hwy. 55, Medina, MN 55340

Phone 1-888-704-5290

Part No. 9923893 Rev 01

Printed in USA

*9923893

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WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our

world-wide family of POLARIS enthusiasts. Be sure to visit us online at

www.polarisindustries.com for the latest news, new product introduc-

tions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and

recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• Low emission vehicles (LEVs)

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 pro-

duced.

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 ser-

vice needs during, and after, the warranty period.

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The following are registered trademarks of POLARIS Industries Inc.:

POLARIS®

THE WAY OUT®

IQ®

IQ SHIFT®

PERC®

is based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrep-

ancies may result between the actual vehicle and the information presented in this publi-

cation. Depictions and/or procedures in this publication are intended for reference use

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as

translations of the original instructions.

Printed in U.S.A.

Owner's Manual P/N 9923893

2013 550 IQ SHIFT / 550 IQ 136 / 550 IQ LXT

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

This section describes safe vehicle operation and identifies warning

decals and their locations.

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

This section identifies 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 . . . . . . . . . . . . . . . . . . . . 40

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

This section explains proper engine break-in, operation of features and

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

This section defines your role, and your dealer's role, in your snowmo-

bile's regular maintenance.

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 98

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 102

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 103

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 119

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile's identification numbers and key number in

the spaces provided. Remove the spare key and store it in a safe place.

Your key can be duplicated only by mating a POLARIS key blank with

one of your existing keys, so if both keys are lost, the ignition switch

must be replaced.

Tunnel VIN

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of the tunnel): _________________________________________

Engine Serial Number (on recoil housing): ____________________________________

Key Number: ___________________________________________________________

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient ref-

erence. It should remain with the snowmobile when the snowmobile is

sold.

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 neces-

sary to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding

clubs.

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INTRODUCTION

Preservation of the Environment

POLARIS is committed to supporting an environmental education cam-

paign. We encourage governments to adopt rigorous safety training pro-

grams that encourage protection of our environment, including wildlife

and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect 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 stan-

dards. 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 manufac-

turing 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 reduc-

tion 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.

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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 sym-

bols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in

death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

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SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 62

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.

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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. Turn off the igni-

tion, 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 and the features available on

some snowmobiles, but under many 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 ride in a position that allows for control of your

vehicle.

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SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be com-

fortable when riding. Be aware of the

weather forecast, especially the wind-

chill, and dress accordingly. See the

chart on page 20.

WARNING! Avoid wearing loose clothing

or long scarves, which can become

entangled in moving parts and cause

serious injury.

Helmet

Wearing a helmet can prevent a

severe head injury. Whenever riding a

POLARIS vehicle, always wear a helmet that meets or exceeds estab-

lished safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

051039

granted approval. The approval number and serial

0006.31

number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever riding a POLARIS vehicle, always wear shatterproof goggles or

use a shatterproof helmet face shield. POLARIS recommends wearing

approved Personal Protective Equipment (PPE) bearing markings such

as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept

clean.

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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 condi-

tions you may encounter. Such equipment may include, but is not lim-

ited 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 cel-

lular telephone.

For added protection, carry the following items on your snowmobile at

all times:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Extra Oil

• Fuel Deicer

• Winter Survival Kit

• Trail Map

• Owner's Manual

• First Aid Kit

• Tool Kit

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.

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to

steer. If equipped, do not exceed carrier and rack weight limits, and do

not allow a passenger to sit on the cargo carrier.

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SAFETY

Operator Safety

Rider Capacity

Driving 1-Up - Some POLARIS snowmobiles are designed for a single

rider only. A decal on the console of these models indicates single rider

operation. Never carry a passenger on a single-rider snowmobile.

Driving 2-Up - Some POLARIS snowmobiles are designed for up to

two riders. A decal on the console of these models indicates that the

vehicle is designed for one operator and one passenger only.

WARNING! Control becomes more difficult with two people on board. More

space is required to make turns, and longer distances are needed for stopping.

Make sure the passenger remains seated behind the driver, facing forward, with

both feet placed firmly on the running boards. Slow down and avoid “jumping”

your snowmobile.

Snowmobiles designed for two riders should never be operated with

more than two people on board. When traveling with a passenger, it’s

the driver’s responsibility to operate the snowmobile safely.

Slow down! Control becomes more difficult with two people on board.

More space is required to make turns, and longer distances are necessary

for stopping.

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 opera-

tion and speed limits. Always be alert and pay attention to the trail

ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling

about 60 feet (18 m) per second. If you look back for only two seconds,

your snowmobile will travel about 120 feet (36 m). If your speed is 60

MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in

two seconds.

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 illumi-

nated by the headlight.

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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 high-

ways. Steep embankments may also hide

your view. Always leave yourself a way

out.

R R

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 snowmobile on a frozen body of

water, be sure the ice is thick enough to support the snowmobile 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.

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SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly

trained and equipped before traveling in

mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped

with a shovel, probe and avalanche

beacon.

You don't have to be snowmobiling on a slope for an avalanche to occur.

Be aware that all of the snow is connected. 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 moun-

tainous terrain.

Before riding in mountainous terrain, call or log on to your local ava-

lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi-

tions, contact local law enforcement in your area, or visit either the

American Avalanche Association online at www.americanavalancheas-

sociation.org or the U.S. Forest Service National Avalanche Center at

www.avalanche.org.

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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.

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SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the machine and

reduce your speed to a minimum. Apply just enough throttle to keep the

clutch engaged, allowing the engine's compression to help slow the

machine and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding

the brakes may cause the brake system to overheat, which may result in brake

failure. 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.

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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.

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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 dynami-

cally balanced before installation. Any tampering may disrupt this pre-

cision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, espe-

cially 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 snowmobile into motion, but always operate within

safety limits and, on 2-up machines, with respect for a passenger.

Maneuverability

While much control and maneuverability is achieved through the steer-

ing system and skis, maximum control is achieved by the shifting of

your body weight. Maneuverability will change for lighter operators or

snowmobiles designed to carry a load or a passenger.

Maintenance

Follow the recommended maintenance program beginning on page 62

of this manual to ensure that all critical components on the snowmobile

are thoroughly inspected by your dealer at specific mileage intervals.

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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 lit-

tle 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.

NOTICE: When operating on icy surfaces or hard-packed snow, avoid overheat-

ing 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 over-

heating.

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SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile condi-

tions 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 driv-

ers should spend some time getting the feel for a machine before

attempting ambitious maneuvers.

• 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.

• Before allowing someone else use your snowmobile, know the extent

of their operating skills. Check to see if they've taken a snowmobile

safety course and have an operator's certificate. For their protection,

as well as yours, make sure they take a snowmobile safety course.

Everyone can benefit from the course.

• Don't “jump” your snowmobile over large drifts or similar terrain.

Jumping may injure your back because of spinal compression that

could occur when the snowmobile impacts the ground. The seat and

suspension of your snowmobile have been designed to provide pro-

tection under normal riding conditions. Your snowmobile is not

intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

• When traveling in a group of snowmobiles, don't tailgate (follow too

closely). Leave enough distance between snowmobiles to provide

ample stopping room and to provide protection from flying snow and

debris. Allow even more distance when driving on slippery surfaces

or when driving in darkness or other low visibility conditions. Be

aware of any snowmobile traffic around your vehicle. Drive defen-

sively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile

unattended.

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SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when tem-

peratures become dangerous for riding.

WIND CHILL CHART (°F)

Wind

Speed

Actual Thermometer Reading (°F)

-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

40 35 30 25 20 15 10

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72

-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

29 23 16

28 22 15

28 21 14

27 20 13

26 19 12

25 18 11

25 17 10

-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

Frostbite in >> 30 min. 10 min. 5 min.

WIND CHILL CHART (°C)

Wind

Speed

Actual Thermometer Reading (°C)

-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

Equivalent Temperature (°C)

Km/h

Calm

-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57

-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.

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SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protec-

tion. Read and follow the instructions of the decals and other warnings

on the snowmobile carefully. If any of the decals depicted in this manual

differ from the decals on your snowmobile, always read and follow the

instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your POLARIS

dealer to purchase a replacement. Replacement safety decals are pro-

vided 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

Do not operate engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself -- see your dealer.

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SAFETY

Safety Decals and Locations

Track Warning

The track warning decal is on the

rear of the tunnel:

Stay clear of track. Do not sit

on seat back. Entanglement

with the track or a fall from seat

back may result in severe

injury or death.

“No Passenger” Warning

Snowmobiles designed for single-

rider use have a warning decal on

the lower right console.

WARNING

This vehicle is designed for

operator only.

“NO PASSENGER”

Passenger Warning

Snowmobiles designed for an oper-

ator and one passenger have a

warning decal on the lower right

console.

WARNING

This vehicle is designed for

operator and “ONE” passenger

only.

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SAFETY

Safety Decals and Locations

Reverse Warning

The reverse warning decal is located

on the upper console:

WARNING

Reverse operation, even at low

speeds, can cause loss of control

resulting in serious injury or

death. To avoid loss of control,

always:

• Look behind before and while

backing up.

• Avoid sharp turns.

• Shift to or from reverse only

when stopped.

• Apply throttle slowly.

NOTE: For more information, see Owner's Manual.

If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH con-

trol to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

Operation Warning

The operation warning decal is

located on the lower console. See

page 24 for the text.

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SAFETY

Safety Decals and Locations

Operation Warning

• To avoid serious injury or death, read and understand all warnings

and the Owner's Manual before operation. If manual is missing, con-

tact a POLARIS dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven

terrain can cause loss of control. Reduce speed and use extreme

caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can

result in insufficient time for you to react to terrain changes, to

avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehi-

cle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located

on the top of the throttle control assembly, to stop the engine. Then

pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate

clothing while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age

requirements.

• When operating with a passenger (on approved models only)

reduce speed and allow extra space for steering and stopping. A

passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads,

steering and braking ability are greatly reduced. Reduce speed and

allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you

should have a proper balance of ski carbides to track studs. See

Owner's Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss

of braking ability.

• Parking brake may relax when used for long periods. Do not leave

brake engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for proper

operation. Make sure hood is latched. Be seated and in position to

control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when

refueling.

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FEATURES

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Taillights

7. Rear Bumper

8. Snow Flap

9. Console Storage Compartment

(if equipped)

10. Suspension

11. Track

12. Skis

13. Nosepan

14. Front Bumper (do not use for pulling or dragging the snowmobile)

15. Passenger Grab Handle (LXT)

16. Passenger Seat (LXT)

17. Passenger Backrest (LXT Accessory)

18. Cargo Bag (LXT Accessory)

19. Cargo Rack (LXT Accessory)

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FEATURES

1. Fuel Filler Cap/Dipstick

2. Recoil Starter Handle

3. Reverse Indicator

4. Headlight Adjuster

5. Speedometer

6. Engine Stop Switch

7. Choke Lever

8. Ignition Switch

9. Brake Lever

10. Parking Brake

11. Handlebar Grip Warmer Switch

12. Thumbwarmer Switch

13. Electronic Reverse Button

14. Headlight Dimmer Switch

15. Throttle Control

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FEATURES

Cargo Bag

The accessory cargo bag is secured to the

rear of the tunnel with straps.

The maximum weight capacity for the

cargo area is 30 lbs. (14 kg). Always

secure cargo before operating. Do not

exceed the weight limit. Do not allow a

passenger to sit on the cargo area.

Adjustable Headlights

Adjust the headlight beam by moving

the adjuster to the left or right.

Passenger Grab Handle

If equipped, the passenger grab handles

can be adjusted for rider preference.

1. Remove the hardware securing the

grab handles to the grab handle

tube.

2. Reposition the grab handles to one

of the three available positions and

reinstall the hardware securely.

Adjustment Positions

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THE PERFECT FIT

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. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

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THE PERFECT FIT

Front Suspension Adjustments

Shock Spring Preload

Increasing spring preload will increase

ski-to-ground pressure. Decreasing spring

preload will decrease ski-to-ground pres-

sure. When adjusting, be sure the springs

on both the left and right sides of the

machine are at the same adjustment.

To change front shock spring preload,

grasp the spring and rotate it.

Increasing the spring preload too much

may adversely affect the handling of the

snowmobile and the performance of the

suspension. Never exceed one inch of pre-

load beyond the factory settings, and

ensure that both sides are adjusted the

same. When decreasing preload, make

sure at least two turns of preload are hold-

ing the spring between the retainer on the

top of the shock and the threaded spring

preload adjuster nut on the shock body.

High

Preload

Low

Preload

Failure to do so could cause the retainer to fall off when the suspension

is fully extended.

Tip: Not all models have shocks with thread adjustable spring preload. See your

dealer for more information.

NOTICE: On some models equipped with a plastic adjuster nut, the nut will

break if it is unscrewed from the threaded body. Do not force the nut if

resistance suddenly increases while you’re turning it.

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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 sus-

pension designs and adjustments involve a compromise, or trade-off.

For example, a suspension set up for snowcross racing would provide a

very stiff ride on the trail. A suspension set up for trail riding would

bottom out harshly on a snowcross course.

Refer to the suspension setup label on your snowmobile, or see your

POLARIS dealer for initial suspension setup information. Additional

adjustments can be made after initial setup. Make adjustments to one

area at a time so you can evaluate the change. For further assistance, see

your dealer.

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THE PERFECT FIT

Rear Suspension Adjustments

Suspension Performance Tips

• 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 setup. These

adjustments are easy to make, involve very little time or effort, and

greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over

worn rail slide. It can also improve top speed.

• 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.

• POLARIS offers track kits for improved flotation in deep snow. See

your dealer for assistance.

Tip: 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 the Pre-Ride Suspension Inspection on page 45.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor-

rect tension and alignment. Refer to the track tension maintenance sec-

tion beginning on page 86.

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THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the rear suspension torsion

spring preload, measure the distance

between the ground and rear bumper. This

is measurement X.

Take the first measurement with no rider

and with the rear suspension at full exten-

sion.

Tip: The rear bumper may need to be lifted

upward slightly to fully extend the rear

suspension.

Next, have the rider drop down hard on

the seat and bounce up and down several

times, collapsing the rear suspension.

With the rider seated, measure the dis-

tance between the ground and the rear

bumper at the exact location used for

measurement X. This is measurement Y.

To determine sag, commonly referred to

as ride-in, subtract measurement Y from

X (sag=X-Y). If the measured sag is

incorrect, adjust the FRA position and/or

rear torsion spring preload.

See

Page

Suspension Recommended Sag Adjustment

IQ (121)

4-5 inches (10-13 cm)

Torsion Spring

Preload

IQ Comfort

(136)

Torsion Spring

Preload

Tip: This is only an initial setup, and final spring preload may vary based on rider

preference and riding conditions. Accessory springs with a higher load rat-

ing are available for some models. Please see your dealer for availability.

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THE PERFECT FIT

IQ Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion spring preload, rotate the three-position cam using

the engine spark plug tool. Adjustment is easiest when the cam is

rotated from low to medium, and then to high. Rotating directly from

low to high will require significantly more effort.

Different rate torsion springs are available if a firmer ride is desired. See

your dealer for more information.

Soft

Medium

Firm

Limiter Strap Position (Ski Pressure)

Ski pressure is set at the factory to

deliver the optimum balance

between ride and handling. If a

rider prefers more ski pressure for

improved steering performance,

adjustments can be made to the

Upper

front limiter straps. Tighten the

straps to increase ski pressure.

Loosen the straps to reduce ski

pressure.

Nuts

1. Remove the nuts and flat

washers from the upper limiter

straps.

2. Relocate the straps to the desired position.

3. Reinstall the nuts and washers. Tighten securely.

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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 To Rear Coupling and the 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 indepen-

dence 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 reducing kickback.

The factory setting is usually adequate for all riders and conditions.

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THE PERFECT FIT

IQ Rear Suspension Adjustments

Suspension Coupling

Rear To Front Coupling and the 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 indepen-

dent 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 (RRSS) - Attributes

Moving the RRSS to a higher position will have the following effects on

the suspension:

• Reduced weight transfer

• Improved chatter bump ride

• Improved cornering performance

• Increased load carrying capacity (2-up)

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THE PERFECT FIT

IQ Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling

weight transfer during acceleration is

by adjusting the rear rear scissor stop

HIGH

LOW

(RRSS). The factory setting is the

best for most trail riding conditions.

MEDIUM

To decrease weight transfer under

acceleration (for improved corner-

ing), rotate the RRSS to a higher

position.

To increase weight transfer or ski lift

during acceleration, rotate the RRSS

to a lower position.

Tip: Your dealer can help you with initial

setup and additional setup instruc-

tions to help you achieve your opti-

mum ride. A scissor stop tool is also

available from your dealer.

RRSS

FRSS

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THE PERFECT FIT

Traction Products

Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist

in turning the snowmobile and to prevent ski wear caused by contact

with roads and other bare terrain. Use carbide skags with studded tracks

to help maintain proper vehicle steering and control. See page 93.

If your snowmobile has carbide skags, it may be necessary to add track

studs to maintain proper vehicle control. Maintain a proper balance

between the number of studs and the length of carbide on the skags (the

more studs you use, the longer the carbide on the skags should be). See

your dealer's track studding chart.

Inspect skags frequently. Worn skags may reduce steering and braking

control on hard-packed snow and ice. Replace worn skags to maintain

proper balance and vehicle control.

WARNING! Loss of control can result in serious personal injury or death.

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.

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed

whenever track studding is used.

Install the appropriate wear strip kit. See your dealer.

Wear strips are designed for a specific stud length. See your dealer's

studding chart for recommended traction accessories.

NOTICE: Whenever wear strips are relocated, be sure there's adequate stud

clearance to the tunnel. Lack of clearance may result in damage to

tunnel.

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THE PERFECT FIT

Handlebar Adjustments

When making handlebar adjustments, always be sure the handlebars,

brake lever and throttle lever operate smoothly and do not contact the

fuel tank, windshield or any other part of the vehicle when the handle-

bars are turned fully to the left or right.

Upper

Bolts

Lower

Bolts

Handlebar Position

Follow these steps to adjust handlebar position.

1. Remove the handlebar cover.

2. Loosen the four upper and four lower adjuster block bolts.

3. Adjust the handlebar to the desired position.

4. Torque the front bolts first, then torque the rear bolts. Torque the

bolts to 15-17 ft. lbs. (20-23 Nm).

5. Reinstall the handlebar cover.

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THE PERFECT FIT

Handlebar Adjustments

Handlebar Angle

Follow these steps to adjust handlebar angle at the handlebar block.

1. Remove the handlebar cover.

2. Loosen the four upper adjuster block bolts.

3. Adjust the handlebar to the desired angle.

4. Torque the bolts to 15-17 ft. lbs. (20-23 Nm).

5. Reinstall the handlebar cover.

Accessories

POLARIS offers a wide range of accessories for your snowmobile to

help make each ride more enjoyable.

Use only POLARIS parts and accessories on your POLARIS snowmo-

bile. Use of unapproved parts and accessories may result in:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies, but is not limited to the following areas: brakes, clutches,

fuel systems, and exhaust systems.

Tip: Exhaust systems are critical safety areas that must use approved POLARIS

parts. Please see your POLARIS dealer for service.

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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 refer-

enced pages.

Item

See Page

Drive Belt Condition

Steering System

Recoil Rope

83, 85

Cooling System Seal

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

42, 43, 77

Taillight/Brakelight/Headlight

Suspension Mounting Bolts

Skags (Wear Bars)

37, 93

Ski Spindle Bolts

Hood Straps/Latches

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

56, 57

Tether Switch/Strap (accessory)

Track Alignment/Condition

Rail Slide Condition

44, 90

Chaincase Oil Level

Injection Oil Level

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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. The manual

is your guide to safe and enjoyable snowmobiling experience.

Throttle Lever

The throttle and brake are the primary controls of your snowmobile.

Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and

smoothly. When released, the lever should immediately return to the

idle position without binding or hesitation. If the throttle does not func-

tion smoothly, or if you discover excessive lever freeplay, DO NOT start

the engine. Have the throttle serviced immediately.

Throttle Safety Switch

Test the throttle safety switch system before the machine is operated.

See page 56.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Brakes

Always check the following items for proper operation before starting

the engine.

Brake Lever Travel

Squeeze the brake lever. It

should move no closer to the

1/2” (1.3 cm)

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 infor-

mation on page 79 or see

your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid

level and condition. Add fluid as needed. See page 78.

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.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

Use the parking brake lever lock only when you want the machine to

remain stationary; for example, when parked on an incline for a period

of five minutes or less.

1. Brake Lever

2. Parking Brake Lever

Lock

3. Master Cylinder Reser-

voir/ Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze

the brake lever tightly and

push forward on the lock.

Hold the lock forward while

releasing the brake lever.

Tip: If the brake lever is squeezed tightly enough, the lock will move freely into

place. Do not force the lock or it may break.

The brake light will illuminate if the parking brake lever lock is set

while the engine is running. It will also illuminate when the service

brake is in use. If the parking brake light does not come on when the

parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return

to the unlock position.

WARNING! If the parking brake lever lock is partially or entirely engaged while

riding, the brakes may overheat, resulting in brake damage. In extreme cases it

could cause a fire, which could result in serious injury or death. Always ensure

that the lever lock is completely disengaged before operating the snowmobile.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

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.

Track

WARNING! 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. Always inspect the track for damage before using the vehicle.

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 lubri-

cation would include frozen bodies of water without snow cover, icy

trails, and no-snow conditions.

Tip: Track damage or failure caused by operation on ice or poor lubrication con-

ditions voids the track warranty.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

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 snowmo-

bile.

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.

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 follow-

ing items on a weekly basis or before any long trip.

Item

Check

Page

Suspension mounting bolts

Rear idler wheel bolts

Rear idler adjusting bolt locknuts

Torque arm bolts

Carrier and bogie wheel bolts

Front torque arm limiter strap

Rail slide

Tightness

Condition

Tension

Lubrication

Condition

Tightness

Track

All rear suspension components

Ski runner/skag

Ski spindle bolts

Tie rod end nuts

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PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining

to snowmobile operation. Never start your snowmobile without check-

ing all components to be sure of proper operation. See Before Starting

the Engine beginning on page 41.

Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the

switch down to stop the engine. Pull it up to allow restarting.

Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

Tether Switch (if equipped)

If your machine has a tether switch, remove the tether from the switch to

make sure the engine stops immediately.

Lighting

Check the headlight (high and low beam), taillight, and brake light.

Replace burned out lamps before operating.

Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

Operating Area

Before driving away, check your surroundings. Be aware of obstacles

and make sure bystanders are a safe distance from the machine.

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OPERATION

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

1. Turn the fuel valve on. See

page 52.

CHOKE POSITIONS

OFF

2. Turn the key to the ON

position.

3. Pull the engine stop switch

up to the RUN position.

1/2 CHOKE

4. If starting a cold engine,

flip the choke toggle to

FULL CHOKE. Do not use

the choke if starting a warm

engine. Do not depress the

throttle until the engine

starts.

FULL CHOKE

CAUTION! To avoid injury and/or engine damage, do not operate the electric

starter or pull-rope starter while the engine is running.

NOTICE: Don't pull the starter rope to the fully extended position and don't allow

it to snap back into the housing. Damage may result.

5. If equipped with electric start, turn the key to START to crank the

engine. Release the key to the ON position when the engine starts.

6. If not equipped with electric start, grasp the starter handle and pull

slowly until the recoil engages; then pull abruptly to crank the

engine.

7. Repeat the cranking procedure as needed until the engine starts.

8. 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 CHOKE position.

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OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. See page 56 for more information about the

engine stop switch and throttle safety switch.

THROTTLE

SYSTEM

Ignition Switch

WHAT IT DOES

CONDITION

Interrupts ignition circuit

Slows jackshaft

All

Brake

Choke

Floods engine

Half throttle or less

Engine Stop Switch

Throttle Safety Switch

Tether Switch (accessory) Interrupts ignition circuit

Interrupts ignition circuit

All

Break-In Period

Engine Break-In

No single action on your part is as important to long, trouble-free

machine life as proper break-in of a new or rebuilt engine. Premix the

first tank of fuel with one pint of POLARIS injection oil for each five

gallons of fuel. This, in addition to the lubrication supplied by the injec-

tion system, will assure proper engine break-in.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts. 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.

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OPERATION

Break-In Period

Oil Injection System

Always check and fill the oil tank when refueling. See page 53.

NOTICE: Serious engine damage can occur without the proper lubrication.

Check the oil tank level often during the first tank of fuel. If the oil level

doesn't go down, contact your dealer immediately.

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection

systems. POLARIS recommends the use of POLARIS Premium 2-

Cycle Semi-Synthetic Oil or VES Gold Plus 2-Cycle Oil for this engine.

See page 102 for the part numbers of POLARIS products.

Never mix brands of oil. Serious chemical reactions can cause injection

system blockage, resulting in serious engine damage. Oils 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.

Drive Belt Break-In

The break-in period for a new drive belt is 30 miles (48 km). During this

time, vary the throttle position under 50% and limit full throttle use.

New drive belts should be washed with warm, soapy water and allowed

to air dry prior to use.

Always take time to warm up the belt and driveline prior to operating

the snowmobile. Free the track and skis from the ground before engag-

ing throttle.

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OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause serious 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. Use a

stable rear support.

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 snow-

mobile at the rear bumper. The track should be about 4” (10 cm) off

the ground.

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.

Tip: 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

to loosen snow and ice.

Slide Rail and Track Cooling

Inadequate cooling and lubrication will lead to overheating of the slide

rail and track, resulting in premature wear and failure.

1. Reduce speeds and frequently drive into fresh snow to allow ade-

quate cooling and polishing of the slide rail and track surfaces.

2. Avoid operating on ice, hard-packed surfaces or roads.

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OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

• Do not overfill the tank. Do not fill the tank neck.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness or death in a short time.

• Turn the fuel valve off whenever the 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.

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OPERATION

Fuel

Your POLARIS engine is designed to run on 87 octane non-oxygenated

or 89 octane oxygenated pump gasoline. There's a great deal of variabil-

ity in the quality of the 87 octane gasoline available across the country,

so we encourage the use of premium fuel when possible. Do not use fuel

containing more than 10% ethanol (including E85).

NOTICE: Using fuels with a lower than recommended octane or operating with

obstructed fuel systems will result in serious and costly engine dam-

age. Always use the recommended fuels for your machine.

Fuel System Deicers

If you use non-oxygenated fuel, POLARIS recommends the regular use

of isopropyl-based fuel system deicer. Add one to two ounces per gallon

(8-16 ml per liter) of gasoline to prevent engine damage resulting from

fuel system icing and lean fuel mixtures. Never use deicers or additives

containing methanol. POLARIS also recommends the use of Carbon

Clean Plus. See page 102 for the part numbers of POLARIS products.

If you use oxygenated fuel containing ethanol, additional alcohol deic-

ers or water absorbing additives should not be used.

Fuel Valve

The fuel valve is located between the

oil bottle and engine intake duct.

Turn the fuel valve off whenever the

snowmobile is stored or parked.

OFF

Turn the fuel valve clockwise to OFF

to shut off the fuel supply.

Turn the valve counter-clockwise to

ON to turn the fuel supply on.

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OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light may flicker at times due to oil movement in

the bottle, but when the light comes on and remains on, add the recom-

mended oil before further operation. See page 49 for oil recommenda-

tions.

Visually check for oil in the bottle. The engine may be operated as long

as oil is visible in the oil tank. If oil is not visible, continued operation

may cause serious engine damage.

Low Oil Level

Maintaining the proper oil level will prevent system aeration and possi-

ble loss of pumping action, which could result in engine damage. This is

especially important when the machine is operated in mountainous ter-

rain.

NOTICE: Operating the snowmobile without adequate engine lubrication can

result in serious engine damage. Always check the oil level when

refueling. Add oil as needed.

Always maintain a visible level of oil in the tank. If oil is not visible,

continued operation may cause serious engine damage. See page 49 for

oil recommendations.

The POLARIS oil cap on the oil bottle is vented to allow proper oil

flow. See your POLARIS dealer for recommended replacement parts.

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OPERATION

Carburetion

NOTICE: Making non-recommended adjustments could result in vehicle or

engine damage as well as denial of warranty claims. We recommend

that all carburetor adjustments be performed by your POLARIS

dealer.

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, for-

eign 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.

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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.

The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and

ambient temperatures of -15° to +5° F. (-26° to -15° C). Carburetors

must be re-calibrated if the snowmobile is operated outside this produc-

tion temperature and/or altitude range. The main jet installed in produc-

tion is not correct for all altitudes and/or temperatures. See page 74 for

more information.

NOTICE: 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 the speci-

fications section of this manual. See page 98.

Tip: 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 encoun-

tered.

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OPERATION

Engine Stop Switch

Push down on the engine

stop switch (X) to ground

out the ignition and stop

the engine quickly. Pull

the switch up to the ON

position to allow restart-

ing.

Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all

pressure is removed from the throttle lever and the throttle cable or

valves do not return to the normal closed position.

WARNING! Operating the snowmobile with a faulty throttle safety switch can

result in serious injury or death in the event of an accident. If the throttle safety

switch does not shut off the engine during a carburetor/throttle system

malfunction, immediately push down the engine stop switch. Do not start the

engine again until the malfunction has been corrected by your dealer.

Test the throttle safety

switch system daily before

operation.

1. Sit on the seat.

2. Start the engine and

allow it to idle.

3. Hold the throttle lever

pin stationary by exert-

ing pressure on the pivot pin in the direction shown in the illustra-

tion.

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

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OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic machine

behavior and loss of control, which could result in serious injury or death. If the

throttle lever does not work properly, DO NOT start the engine.

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor to determine what

caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times.

The lever and cable must return to the idle position quickly and

completely.

4. If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5. If the engine doesn't start, take the snowmobile to an authorized

POLARIS dealer for service.

Excessive freeplay in the throttle cable may cause the safety switch to

activate, preventing the engine from starting. If this occurs, return the

machine to an authorized POLARIS dealer for service.

If an emergency exists and it's necessary to start the engine, the throttle

safety switch and engine stop switch may be disconnected from the wire

harness. When these switches are disconnected, the ignition key switch

must be used to shut off the engine. DO NOT continue to operate the

machine with the throttle safety switch disconnected. Return the

machine to an authorized POLARIS dealer for service as soon as possi-

ble.

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OPERATION

Electronic Reverse (PERC)

Electronic reverse will activate only if the engine RPM is below 4000. If

your machine is running at an altitude of over 6000 feet, adjust the igni-

tion setting as described on page 59. Always make sure the vehicle is

stopped and the engine is running at idle before shifting to reverse

Tip: The engine will activate a misfire mode and begin to stutter after 45 sec-

onds in reverse. This feature protects the engine from overheating and will

reset when it is shifted into forward or when the engine is stopped and

restarted.

WARNING! Improper reverse operation, even at low speeds, may cause loss of

control, resulting in serious injury or death. Damage will occur to the chaincase

or transmission if shifting is attempted when the engine is operating above idle

speed.

• Shift to or from reverse only when the snowmobile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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OPERATION

Electronic Reverse (PERC)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your vehicle is clear.

3. Push the yellow reverse button on the left-hand control for one sec-

ond, then release. The engine will automatically reduce RPM and

start a reverse rotation. A flashing reverse light on the instrument

panel will indicate that the machine is in reverse.

4. Apply the throttle slowly to make sure the machine is in reverse.

Tip: The maximum engine RPM will be 6000 when in reverse.

Tip: If the engine stops running, the snowmobile will be in forward gear when it's

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The

engine will slow and and begin to rotate forward. The light on the

instrument panel will shut off.

3. Apply the throttle slowly to make sure the machine is in forward.

Altitude Setting

At higher altitudes (above 6000 feet), the engine will require a different

ignition setting to improve the success of the reverse system. To set for a

higher altitude, start the engine and hold the button down until the light

on the instrument panel flashes rapidly, then release the button.

To set the reverse for lower elevations, continue holding the button

down until the reverse indicator light blinks slowly. Once set, it's stored

in memory until changed, whether the machine is running or not.

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OPERATION

Towing

Do not use the front bumper to pull or drag the snowmobile. The front

bumper is not designed for this type of use and may detach from the

vehicle if force is applied.

For your safety, do not attempt to use a tow hitch until you've read the

following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily

collide with the rear of the snowmobile or other objects, resulting in serious

injury or death. 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 someone ride on the

towed snowmobile to operate the brake and steering when necessary.

NOTICE: 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.

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MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or

repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission con-

trol information (ECI) label and a factory-installed emissions informa-

tion hangtag. These items are required by U.S. Environmental

Protection Agency regulations. The ECI label is permanently affixed to

either the right side of the tunnel or the engine recoil cover. The ECI

label should not be removed, even after you purchase the snowmobile.

You may remove the factory-installed emissions information hangtag,

which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

octane level of 87 (R+M)/2. If your snowmobile is equipped with a

check engine light and it comes on, you must take your snowmobile to a

qualified dealer for diagnostic service. Specifications and adjustments

for engine tune-ups are located in the Service Manual, which is avail-

able to your qualified service technician. Reverse (if equipped) must not

be engaged during engine tune-ups.

Owner's Responsibilities

Please read the U.S.A EPA Emissions Limited Warranty beginning on

page 117, and read the maintenance section of your owner's manual.

You are responsible for ensuring that the specified maintenance is per-

formed. POLARIS recommends that you contact an authorized

POLARIS dealer to perform any service that may be necessary.

Non-ionizing Radiation

This vehicle emits some electromagnetic energy. People with active or

non-active implantable medical devices (such as heart monitoring or

controlling devices) should review the limitations of their device and the

applicable electromagnetic standards and directives that apply to this

vehicle.

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MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow

recommended regular maintenance and perform service checks as out-

lined in this manual. Record maintenance and service in the Mainte-

nance Log beginning on page 119.

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 per-

formed by a qualified service technician. For continued optimum perfor-

mance 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 regis-

tered owner. If, during the course of the warranty period, part failures

occur as a result of owner neglect in performing recommended regular

maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjust-

ments to your snowmobile. If you're not familiar with safe service or

adjustment procedures and the use of tools, or if you don't feel comfort-

able performing these tasks yourself, contact an authorized POLARIS

dealer for service.

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the snowmo-

bile on its side for service or inspection.

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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.

Item

See

Frequency

1000 mi.

(240 km) (800 km) (1600 km) (3200 km)

Page

150 mi.

500 mi.

2000 mi.

Pre-

Season

CLUTCH

Clutch Alignment Offset

(without belt)

Drive Belt Condition

Clutches (disassemble)

Belt Tension

Clutch Sheaves

ENGINE

Engine Mounts

Engine Mounting Plate

Engine Torque Stop

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

Recoil Rope

Spark Plug Condition

Exhaust Pipe

Exhaust Retaining

Springs

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Frequency

1000 mi.

(240 km) (800 km) (1600 km) (3200 km)

Page

150 mi.

500 mi.

2000 mi.

Pre-

Season

BRAKES

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads

Brake Disc

Parking Brake

Brake System

Brake Fluid

42, 77

FUEL MANAGEMENT

Pilot Air Screws

Carburetor

(synchronize)

Idle RPM

Throttle Lever

Oil Pump Lever

(synchronize)

Throttle Cable

Choke Cable

Choke

Vent Lines

Fuel Lines

Fuel Filter

Oil Filter

Oil Lines

Air Box

Drain and Water Traps

ELECTRICAL

Auxiliary Shut-Off

Switch

Throttle Safety Switch

Ignition Switch

Taillight

Brakelight

Headlight

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Frequency

1000 mi.

(240 km) (800 km) (1600 km) (3200 km)

Page

150 mi.

500 mi.

2000 mi.

Pre-

Season

CHASSIS

Ski Toe Alignment

Suspension Mounting

Bolts

Steering Fasteners

Rear Suspension Fas-

teners

Suspension Shock Oil

Cooling System

Drive Shaft Bearing

Jackshaft Bearings

Skags (Wear Bars)

Ski Saddle/Spindle

Bolts

Steering Arm(s)

Drive Chain Tension

Hood Latches

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

Rear Suspension Pivot

Shafts

Camber Alignment

Handlebar Centering

Tether Switch and Strap

Track Alignment

Track Tension

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Lubrication

Front Suspension

The front suspension does not require lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS Premium All Sea-

son Grease at the intervals outlined in the Periodic Maintenance Table

beginning on page 62 and before seasonal storage. When operating in

heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the sus-

pension. For more information about suspension lubrication and adjust-

ments, see your POLARIS dealer.

IQ Rear Suspension (121)

IQ Comfort Rear Suspension (136)

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MAINTENANCE

Lubrication

Driveshaft Bearing

Inject grease into the fitting on the

speedometer sensor housing until

grease purges from the seal on the

inside of the tunnel. This should

take approximately two pumps. Do

not use more than four pumps.

Throttle Cable

Lubricate the throttle cable lightly

with grease or oil. With the engine

off, turn the handlebars to the left

and lubricate liberally as shown.

Choke and Choke Cable

Lubricate the choke slide and cables

lightly with oil or grease. Before

turning the engine off, operate the

choke intermittently to draw mois-

ture out of the choke plunger area

and reduce the possibility of the

choke becoming frozen.

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MAINTENANCE

Lubrication

Chaincase Oil

Check the chaincase oil level at the

intervals outlined in the maintenance

charts beginning on page 62. The sight

glass (1) is located on the lower rear of

the chaincase. Maintain the oil level at

or slightly below the center of the sight

glass (2). Change the chaincase oil after

the first 500 miles (800 km), then every

1000 miles (1600 km) or seasonally.

POLARIS recommends the use of

POLARIS Synthetic Chaincase Lube.

See page 102 for the part numbers of

POLARIS products.

Oil Check

1. Position the vehicle on a level sur-

face.

2. View the oil level at the sight glass.

3. Remove the fill plug (3) and add the

recommended oil as needed. Do not

overfill.

4. Reinstall the fill plug, making sure it

is seated properly.

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MAINTENANCE

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the drain plug (4) and drain

the oil into a drain pan. Allow the oil

to drain completely.

3. Clean off all metal shavings from the

plug.

4. Install a new sealing washer on the

drain plug.

Tip: The sealing surfaces on the drain plug and the oil tank should be clean and

free of burrs, nicks or scratches.

5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

6. Remove the fill plug. Clean off all metal shavings from the plug.

7. Add 9 oz. (265 ml) of the recommended oil. Do not overfill.

8. Reinstall the fill plug, making sure it is seated properly.

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MAINTENANCE

Spark Plugs

It’s very important to use the correct spark plug for your machine. A

spark plug with a heat range too high will cause engine damage. A spark

plug with a heat range too low will cause excessive fouling and engine

malfunctioning. Change the spark plugs every 2000-2500 miles (3200-

4000 km).

NOTICE: A spark plug with a heat range too high will always cause engine dam-

age if the engine is operated in conditions more severe than intended

for that plug. Always use the spark plugs recommended for your

snowmobile. See the specifications section beginning on page 98.

A new engine can cause temporary spark plug fouling due to the preser-

vative added during the assembly process. Avoid prolonged idle speeds,

which cause plug fouling and carbonization.

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

• Always carry spare 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.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too

light in color. Before changing spark plug heat ranges, be sure the correct

main jet is installed in the carburetor(s). Refer to the Owner's Manual Sup-

plement or see your dealer.

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MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect carburetor/throttle

body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended injection oil, improper use of the choke, or incor-

rect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Rotate the spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Reinstall the spark plug cap.

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MAINTENANCE

Intake Filters

The intake foam filters limit snow

ingestion into the intake system.

When operating in loose powder

snow, check the foam filters period-

ically to remove any accumulation

of snow.

NOTICE: Operating the snowmobile

with the intake filters removed

may cause carburetor icing.

The result will be poor fuel

economy or carburetor mal-

function. Always reinstall the

intake filters before operating

the snowmobile.

Oil Lines

Inspect oil line condition every 1000 miles (1600 km).

Oil Filter

The oil filter is located at the side of

the oil tank. Have your dealer change

the oil filter and bleed the system

annually or every 1000 miles (1600

km).

Tip: The direction of the arrows indicates

the direction of flow through the fil-

ter.

Fuel Pump

All fuel pump service must be performed by an authorized POLARIS

dealer. Do not attempt to service the fuel pump.

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MAINTENANCE

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the under-tank fuel filter

every 1000 miles (or annually).

Inspect the fuel lines regularly for signs of deterioration or damage.

Always check fuel line condition after periods of storage. Normal dete-

rioration from weather and fuel compounds may occur. Replace worn or

damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

lines may cause damage to the lines. If a fuel line has been damaged

or kinked, replace it promptly.

Cooling System

Inspect the fan intake and outlet edge seal at the input and output for

cracks, loosening of duct and blockage or obstructions. Make any neces-

sary repairs promptly.

Exhaust System

Check the exhaust system for wear or damage at approximately 2000

miles (3200 km). Always allow the engine and exhaust system to cool

completely before inspecting.

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for

the exhaust system to cool. Never perform this procedure with the engine

running.

1. Open the hood and inspect the muffler and pipes for cracks or dam-

age.

2. Check for weak or missing retaining springs or damper/support

grommets.

3. Check for loose clamps on the pipe covers.

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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.

NOTICE: Operating the snowmobile with incorrect jetting can result in serious

engine damage. Have your POLARIS dealer perform all carburetor

adjustments to ensure all adjustments are done correctly.

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:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

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MAINTENANCE

Carburetor Water/Sediment Trap

Most POLARIS snowmobiles contain patented carburetor bowl water/

sediment traps located at the bottom of each carburetor. The trap, con-

sisting of a hose with a plug, should be drained about every 1000 miles

(1600 km) and inspected for contamination.

WARNING! When draining the traps, fuel spillage will occur. Always work in a

well ventilated area away from anything that may cause the fuel to ignite, such

as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel

warnings on page 51.

Cleaning Procedure

1. Turn the fuel valve off.

2. Place a container or shop

towels below the plug to

catch drained fuel.

3. Slide the clamp (1) away

from the drain plug (2) and

remove the drain plug from

the sediment tube.

4. Wipe residue from the plug and reinstall it. Reposition and tighten

the clamp.

5. Repeat the draining procedure for any remaining traps.

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MAINTENANCE

Drive Chain Tension

Check drive chain tension weekly and

before each long trip. To obtain correct

chain tension:

1. Rotate the driven clutch counter-

clockwise to move all chain slack to

the tensioner side. Lock the brake

lever lock, or have an assistant hold

the brake lever firmly.

2. Loosen the adjuster bolt jam nut (1).

3. Finger tighten the adjuster bolt (2)

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. Torque to 21 ft.

lbs. (28 Nm).

5. Release the brake lever lock.

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MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect brake lever travel before each use of the snowmobile. See page

42.

Brake pads must be replaced when the brake pad material becomes thin-

ner than the backing plate (approximately 1/16” or 1.5 mm). A kit is

available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death.

Properly functioning brakes are vital to your safety. 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” or 1.5 mm

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material

(Replace when thickness is

less than 1/16” or 1.5 mm).

Excessive Lever Travel

Hydraulic brakes are self-

adjusting, but if excessive

brake pad clearance develops,

bring the machine to an autho-

rized POLARIS dealer for

inspection and adjustment.

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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 serious injury.

The brake fluid level can be seen through a plastic sight glass in the

brake reservoir. If the fluid is sufficient, the sight glass will be black. If

the sight glass is any color other than black, add brake fluid.

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.

Replace brake fluid at least every two years with POLARIS DOT 4 high

temperature brake fluid. See page 102 for the part numbers of POLARIS

products.

NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe

up spills immediately.

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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 possi-

ble. The reservoir must be in this position to minimize the possibility of

air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir

opening. 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 78.

8. Reinstall the gasket and cover.

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MAINTENANCE

Lights

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. If fin-

gers do touch the bulb, clean it with an alcohol-moistened towel.

Headlight Bulb Removal

1. Remove the plenum covering

from the headlight assembly.

2. Lift the rubber boot to expose

the bulb.

3. Push down on the spring (1) to

release it from the housing.

4. With the wire harness (2)

attached to the bulb (3), with-

draw the bulb from the housing.

5. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

Headlight Bulb Installation

1. Hold the bulb by its metal base and install it into the wire harness.

Tip: Recommended replacement bulbs include H4, HB2 and 9003 bulbs.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Verify headlight aim.

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MAINTENANCE

Lights

Taillight/Brakelight Replacement

1. Remove the screws securing the taillight lens. Remove the lens.

2. Push the bulb inward and turn it counter-clockwise to remove it.

3. Install a new bulb. Push the bulb inward and turn it clockwise to

secure it.

4. Reinstall the taillight lens.

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MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To

maintain optimum performance, clean with non-oil based cleaners such

as isopropyl alcohol.

NOTICE: If you become aware of higher than normal clutch engagement or an

unusual vibration or shift pattern, see your dealer immediately. Do not

operate the machine until repairs have been made.

All clutch maintenance and repairs must be performed by an autho-

rized POLARIS dealer. Any unauthorized modifications to clutches,

such as adding or removing weights, will void the warranty.

The bushings in the weights and rollers of POLARIS clutches are

made of a material that may be damaged if lubricated. Do not lubri-

cate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-

mance. See your dealer for service and adjustments. A special tool is

required to check for proper alignment.

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MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt, and

always carry a spare. Inspect the belt for signs of excessive wear: frayed

edges, missing cogs, cracks and excessive looseness. Replace the belt if

any of these conditions exist. See Drive Belt Troubleshooting on page

107.

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

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete

stop.

3. Lock the parking brake.

4. Open the hood.

5. Remove the left side panel.

6. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to

remove the belt.

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MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back the

slack. The belt cord line

should be flush with, or

slightly above, the outer cir-

cumference of the driven

clutch sheaves. The belt will

seat itself in the driven clutch

during the break-in period.

Adjust the belt ride-out after

the break-in period by read-

justing belt deflection.

Tip: To ensure satisfactory belt life, install belts so they operate in the same

direction of rotation by positioning the identification numbers so that you

can read them. If required, separate the sheaves as outlined in the belt

removal procedures.

2. Rotate the L-wrench counter-clockwise to tighten the sheaves while

working the belt to the outer edge of the sheaves.

3. Remove the L-wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

6. Break in the new belt. See page 49.

Drive Belt

Belt width and length must match the center distance of the clutches and

sheave width of the drive clutch. POLARIS recommends the use of

O.E.M. belts. Other belts may match the dimensions, but can drastically

change the shift pattern, resulting in poor performance.

Tip: A worn belt will continue to function, but will not deliver maximum perfor-

mance. Always carry a spare belt in case of an emergency.

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MAINTENANCE

Clutch System

Drive Belt Deflection

Measure belt deflection with both

clutches at rest and in their full

neutral position.

Place a straight edge (1) on the

belt and apply downward pressure

while measuring at point 2. This

measurement should be 1 1/4 inch

(3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave

of the clutch (see page 83). Turn the wrench clockwise slightly to

remove pressure from the sheaves.

2. Loosen the 7/16-inch jam nut.

3. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward

(counter-clockwise) to decrease the distance.

4. Tighten the jam nut. Store the L-wrench in the tool kit.

Torque Stop

Periodically check torque stop

.010-.030 inch

clearance. With clutches in

(.25-.75 mm)

proper alignment, the torque

stop clearance should be .010-

.030 inch (.25-.75 mm) from

the engine case.

Adjust if necessary, and lock

the jam nut.

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MAINTENANCE

Track Maintenance

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the

machine, which could cause serious injury or death. Never operate with a

damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift and

support the rear of the snow-

mobile off the ground.

2. Rotate the track by hand to

check for damage.

3. Carefully examine the track

along the entire length of

each rod (X). Bend the track

to check for breakage.

4. Replace the track if any rod

damage is found.

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MAINTENANCE

Track Maintenance

Track Lubrication

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of

braking ability, which can result in serious injury or death. Avoid operating for

extended periods on ice and other surfaces that have little or no snow for

lubrication.

The slide rail needs snow for lubrication. Excessive wear indicates

insufficient lubrication. A new rail slide can cause faster heat build-up

in limited lubrication, resulting in excessive wear.

Tip: If excessive rail slide wear occurs due to poor snow conditions, additional

wheel kits are available. See your dealer for more information.

Tip: Track damage or failure caused by operation on ice or under other poor

lubrication conditions will void the track warranty.

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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 cor-

rect tension and alignment.

TRACK TENSION DATA CHART

Measurement

Location

Slack

Measurement

Suspension

Weight

IQ (121)

10 lbs. (4.54 kg)

16 in. (40 cm)

ahead of rear

idler shaft

7/8-1 1/8 in.

(2.2-2.9 cm)

IQ Comfort (136) 10 lbs. (4.54 kg)

16" (40 cm)

ahead of rear

idler shaft

7/8-1 1/8 in.

(2.2-2.9 cm)

Tip: Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine 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 chart) ahead of the center of the rear

idler wheel. Measure at the point where the weight is hanging.

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MAINTENANCE

Track Maintenance

Track Tension

4. Check for specified slack between the wear surface of the track clip

and the plastic slider. Refer to the Track Tension Data Chart on page

88.

If the track needs adjustment:

5. Loosen the rear idler shaft bolt.

6. Loosen the locknuts.

Adjusting Screw

Lock Nut

Slack Measurement

Shaft

Bolt

Track

10 lbs.

16 in. (40 cm)

(4.54 kg)

7. Tighten or loosen the track adjusting screws to provide equal adjust-

ment on both sides of the track.

8. Repeat the measurement on the other side of the track.

Tip: Check more frequently when the machine is new.

9. Start the machine and slowly rotate the track at least five revolu-

tions. Let the track come to a stop (do not apply brakes).

10. Check track alignment (see page 90) and adjust as necessary.

11. Tighten the locknuts.

12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).

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MAINTENANCE

Track Maintenance

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).

3. Inspect track alignment by

looking through the track

window to make sure the

rails (X) are evenly spaced

on each side. If the track

runs to the left, loosen the

idler shaft bolts, then

loosen the left locknut and

tighten the left adjusting

bolt. If the track runs to the

right, loosen the idler shaft

bolts, then loosen the right

locknut and tighten the

right adjusting bolt.

4. After adjustments are com-

plete, tighten the locknuts

and torque idler shaft bolts

to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

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MAINTENANCE

Steering System

Steering Inspection and Adjustment

Each week, or before a long ride, check all steering system fasteners and

tighten if necessary.

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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.

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10

inches (25.4 cm) forward from the center of the ski mounting bolt.

See illustration. At this point, measure between the skis. This is

measurement X.

3. Perform the same measurement rearward from the center of the ski

mounting bolt. This is measurement Y.

4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than

the Y measurement. If the skis are misaligned, see your dealer for

alignment correction as camber adjustment may also be affected.

10 in.

(25.4 cm)

10 in.

(25.4 cm)

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MAINTENANCE

Steering System

Ski Skags

See your dealer's studding chart for recommended skags. If you install

longer or more aggressive carbide skags than the original equipment, it

may also be necessary to add track studs to maintain proper vehicle con-

trol while turning on hard-packed snow or ice.

WARNING! Worn skis and/or skags will adversely affect handling. Loss of

vehicle control may result, causing serious injury or death.

Check skags before each use of the snowmobile to ensure positive steer-

ing characteristics. Skags must be replaced when worn to half their orig-

inal diameter.

Tip: 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 inches (15.2

cm) from the ground.

2. Remove the attaching nuts

and pry the skag downward.

3. Remove the rear end of the

skag.

4. Remove the front end of the

skag.

5. Reverse the steps to install a

skag.

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MAINTENANCE

Steering System

Rail Slide Wear

For ease of inspection, all

POLARIS rail slides have a

wear limit indicator groove

to indicate the minimum per-

missible slide thickness.

Minimum

Thickness

Replace the rail slides if they

are worn to the top of the

groove at any point along

their length. Failure to do so

may result in permanent

Replace when

worn to top of

groove

damage to the track or rails.

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MAINTENANCE

Daily Storage

At the end of each ride, park the snowmobile on a level surface and sup-

port it at the rear with an appropriate track stand. The track should be

suspended approximately 4 inches (10 cm) off the ground.

Remove the key and cover the machine.

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

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. See page 102 for the part numbers of POLARIS

products.

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 sur-

faces 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 sun-

light, and covered with a fabric snowmobile cover. Plastic tarp may

cause condensation to form and damage snowmobile components.

Controls and Linkage

Lubricate all bushings and cables as outlined in the Periodic Mainte-

nance Table beginning on page 63.

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MAINTENANCE

Extended Storage

Bearings

Grease the jackshaft and drive shaft clutch side bearings with POLARIS

Premium All-Season Grease or a similar high quality grease to prevent

corrosion.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate

clutch components, except the driven clutch shaft bushing as outlined in

the Master Repair Manual. See your dealer.

Engine and Carburetor Protection

Proper preparation of the engine and fuel system is vital to the preven-

tion 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 container.

Always add Premium Carbon Clean or a fuel conditioner/stabilizer to

the fuel tank. Follow the instructions on the container, running the

engine for five minutes to get additives through the entire fuel system.

Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.

If stabilizer is not used, drain the carburetors by removing the water trap

drain plugs. See page 75.

Tip: Jet restriction caused by improper storage can cause lean conditions and

very poor slow speed driving quality.

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MAINTENANCE

Extended Storage

Electrical Connections

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.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Turn the fuel valve off. See page 52.

2. Be sure the fuel cap and oil cap are installed correctly.

3. Always tie the snowmobile to the transporting unit securely using

suitable straps.

4. Remove the ignition key to prevent loss.

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SPECIFICATIONS

550 IQ SHIFT

Capacities and Dimensions

Body Style

Rider Capacity

Coolant Capacity

Fuel Capacity

Oil Capacity

N/A

11.5 gal. (43.5 l)

3 qts. (2.8 l)

8.96 oz. (265 ml)

115 in. (292 cm)

47.25 in. (120 cm)

44.5 in. (113 cm)

Hayes Phantom DOT 4

11 in. (28 cm)

3211121

Gearcase Oil Capacity

Length

Width

Height

Brake Type

Drive Clutch Center Distance

Drive Belt P/N

Clutch Type

P-85

Reverse Transmission

Electronic Reverse

Engine and Cooling

Engine

EC55PM0124

Displacement

Cylinders

544 cc

Bore x Stroke (mm)

Alternator Output

Carburetor/Throttle Body

Carburetor Model

Idle RPM

73x65

280 watt

2 Mikuni

VM34

1700 +/- 200

Cooling

Fan Air

Ignition Type

Ignition Timing

Spark Plug / Gap

Kokusan 16 Bit ER

15° BTDC @ 1600 RPM, 17° BTDC @ 6500 RPM

NGK BR9ES / .028 in. (0.70 mm)

Features

Electric Fuel Gauge

Electric Start

N/A

Accessory (Standard on ES models)

Low Oil Light

Parking Brake

Speedometer

Standard

Accessory

Tachometer

Carburetor Settings

Main Jet

250

Pilot Jet

Jet Needle

6BGY48

Q-0 (480)

Needle Jet

Cutaway

Throttle Gap Under CA

6.98 mm / .275 in.

Fuel Screw (from fully seated)

Air Screw (from fully seated)

Pilot Air Jet

N/A

1.5 Turns

2.5

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SPECIFICATIONS

550 IQ SHIFT

Carburetor Jetting

*Shaded cells indicate factory settings.

AMBIENT TEMPERATURE

°F:

°C:

Below -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above

-25

+60

ALTITUDE

Meters

Below -34 to -23 -26 to -15 -18 to -7

-9 to +2

-1 to +10

+7 to +18 Above

(Feet)

-35

+16

Main Jet

Pilot Jet

270

260

250

240

230

220

210

200

0-600

(0-2000)

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

260

240

220

210

250

230

210

200

240

220

200

190

230

210

190

180

220

200

180

175

210

200

180

170

210

190

170

160

200

180

170

160

600-1200

(2000-4000)

1200-1800

(4000-6000)

1800-2400

(6000-8000)

2400-3000

(8000-

10000)

Clip Position

Main Jet

Pilot Jet

200

190

180

170

160

150

3000-3700

(10000-

12000)

Clip Position

The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR

1051.115(d)(3) and is an acceptable alternative to the use of tamper-resistant features.

550 IQ SHIFT

Clutching Chart

ALTITUDE

Drive Clutch

Shift Weight

Drive Clutch

Spring

Driven Clutch

Spring

Driven Helix

Chaincase

Gearing/

Pitch

Meters (Feet)

*Shaded cells indicate factory settings.

0-600

10-64

120/310 Black 130/180 P2 Tab 42S P2N N/A

(7043681) (7043515) (5137155)

20:41

76P

(0-2000)

(1321585)

600-1200

10-62

120/310 Black 130/180 P2 Tab 42S P2N N/A

(7043681) (7043515) (5137155)

20:41

76P

(2000-4000)

(1321586)

1200-1800

10-62

120/310 Black 130/180 P2 Tab 42S P2N N/A

(7043681) (7043515) (5137155)

20:41

76P

(4000-6000)

(1321586)

1800-2400

10-60

120/310 Black 130/180 P2 Tab 42S P2N N/A

(7043681) (7043515) (5137155)

19:41

76P

(6000-8000)

(1321587)

2400-3000

10-58

120/310 Black 130/180 P2 Tab 42S P2N N/A

19:41

76P

(8000-10000)

(1321588)

(7043681)

(7043515)

(5137155)

3000-3600

10-56

Dark Blue

(7041526)

130/180 P2 Tab 42S P2N N/A

19:41

76P

(10000-12000)

(1321684)

(7043515) (5137155)

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SPECIFICATIONS

550 IQ 136 / 550 IQ LXT

Capacities and Dimensions

Body Style

Rider Capacity

Shift 136/ES: 1 Rider

IQ LXT: 2 Riders

N/A

11.5 gal. (43.5 l)

3 qts. (2.8 l)

Coolant Capacity

Fuel Capacity

Oil Capacity

Gearcase Oil Capacity

Length

Width

Height

8.96 oz. (265 ml)

125 in. (318 cm)

47.25 in. (120 cm)

44.5 in. (113 cm) (low windshield)

48 in. (122 cm) (high windshield)

Hayes Phantom DOT 4

11 in. (28 cm)

Brake Type

Drive Clutch Center Distance

Drive Belt P/N

3211121

Clutch Type

Reverse Transmission

P-85

Electronic Reverse

Engine and Cooling

Engine

EC55PM0124

Displacement

Cylinders

544 cc

Bore x Stroke (mm)

Alternator Output

Carburetor/Throttle Body

Carburetor Model

Idle RPM

73x65

280 watt

2 Mikuni

VM34

1700 +/- 200

Cooling

Fan Air

Ignition Type

Ignition Timing

Spark Plug / Gap

Kokusan 16 Bit ER

15° BTDC @ 1600 RPM, 17° BTDC @ 6500 RPM

NGK BR9ES / .028 in. (0.70 mm)

Features

Electric Fuel Gauge

Electric Start

N/A

Accessory (Standard on LXT and ES models)

Low Oil Light

Parking Brake

Speedometer

Standard

Accessory

Tachometer

Carburetor Settings

Main Jet

250

Pilot Jet

Jet Needle

6BGY48

Q-0 (480)

Needle Jet

Cutaway

Throttle Gap Under CA

6.98 mm / .275 in.

Fuel Screw (from fully seated)

Air Screw (from fully seated)

Pilot Air Jet

N/A

1.5 Turns

2.5

100

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SPECIFICATIONS

550 IQ 136 / 550 IQ LXT

Carburetor Jetting

*Shaded cells indicate factory settings.

AMBIENT TEMPERATURE

°F:

°C:

Below -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above

-25

+60

ALTITUDE

Meters

Below -34 to -23 -26 to -15 -18 to -7

-9 to +2

-1 to +10

+7 to +18 Above

(Feet)

-35

+16

Main Jet

Pilot Jet

270

260

250

240

230

220

210

200

0-600

(0-2000)

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

260

240

220

210

250

230

210

200

240

220

200

190

230

210

190

180

220

200

180

175

210

200

180

170

210

190

170

160

200

180

170

160

600-1200

(2000-4000)

1200-1800

(4000-6000)

1800-2400

(6000-8000)

2400-3000

(8000-

10000)

Clip Position

Main Jet

Pilot Jet

200

190

180

170

160

150

3000-3700

(10000-

12000)

Clip Position

The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR

1051.115(d)(3) and is an acceptable alternative to the use of tamper-resistant features.

550 IQ 136 / 550 IQ LXT

Clutching Chart

ALTITUDE

Drive Clutch

Shift Weight

Drive Clutch

Spring

Driven Clutch

Spring

Driven Helix

Chaincase

Gearing/

Pitch

Meters (Feet)

*Shaded cells indicate factory settings.

0-600

11-66

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(0-2000)

(1322597)

600-1200

11-64 CS

(1322604)

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(2000-4000)

1200-1800

11-62

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(4000-6000)

(1322862)

1800-2400

11-60

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(6000-8000)

(1322863)

2400-3000

11-58

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(8000-10000)

(1322864)

3000-3600

11-56

90-280 Black

(7043677)

130/180 P2 Tab 42S P2N N/A

(7043515) (5137155)

18:42

76P

(10000-12000)

(1322865)

101

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

2870791

2875035

2875036

2875038

2877882

2877883

2877884

Fogging Oil (12 oz./355 ml Aerosol)

Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l)

Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l)

Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l)

VES Gold Plus 2-Cycle Oil (qt./.95 l)

VES Gold Plus 2-Cycle Oil (gal./3.8 l)

VES Gold Plus 2-Cycle Oil (2.5 gal./9.5 l)

Chaincase Lubricants

2873105

2872951

Synthetic Chaincase Lubricant (qt./.95 l)

Synthetic Chaincase Lubricant (12 oz./355 ml)

Grease/Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz./89 ml)

Premium All Season Grease (3 oz./89 ml cartridge)

Premium All Season Grease (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel™)

2871312

2871322

2871423

2871329

Additives/Miscellaneous

2871326

2870652

2872189

2872893

2870505

2872889

2872890

Carbon Clean Plus

Fuel Stabilizer

DOT 4 Brake Fluid

Engine Degreaser

Isopropyl

Brake and Clutch Cleaner

Carb and Throttle Body Cleaner

102

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TROUBLESHOOTING

Engine Troubleshooting

Unless you have experience and training in two-cycle engine repair, see

your dealer if technical problems arise.

Problem

Probable Cause Solution

Erratic engine oper- Drive clutch binding • Disassemble drive clutch to inspect

ating RPM during

acceleration or load

variations

shift weights for wear and free oper-

ation. SEE YOUR DEALER.

• Clean and polish stationary shaft

hub.

Driven clutch mal-

function

• Replace ramp buttons and rollers.

SEE YOUR DEALER.

• Inspect movable sheaves for exces-

sive bushing clearance and replace if

necessary. SEE YOUR DEALER.

Harsh drive clutch

engagement

Drive belt worn or

too narrow

• Replace the drive belt.

Excessive belt/

• SEE YOUR DEALER.

sheave clearance

Drive belt turns over Wrong belt for appli- • Replace the drive belt.

cation

Clutch alignment out • Adjust alignment offset. SEE YOUR

of spec

DEALER.

Engine mount bro-

ken or loose

• Inspect and adjust or replace. SEE

YOUR DEALER.

Machine fails to

move

Clutch jammed

• Check for twisted belt, broken

spring, sticking weights, lubrica-

tion. SEE YOUR DEALER.

Track jammed

• Foreign object may be caught or the

rail slide melted to the track clips

due to lack of lubrication.

• Track may be iced up or frozen to

the ground.

Chaincase sprocket

or chain jammed or

broken

• Chain is loose or broken or chain

tightener is loose. SEE YOUR

DEALER.

Engine stutters in

reverse

Misfire mode has

activated to prevent

engine overheat

• Shift to forward or restart the engine

to clear the misfire mode.

103

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive sys-

tem

Broken drive clutch • SEE YOUR DEALER.

components

Bearing failure/

• SEE YOUR DEALER.

chaincase, jackshaft,

or front drive shaft

Drive belt surface

flat spots

• Inspect and replace as needed.

Drive chain loose

• Inspect and adjust (or replace).

• SEE YOUR DEALER.

Drive chain worn,

sprocket teeth bro-

ken

Poor low RPM per-

formance

Worn drive belt

• Inspect and replace as needed.

• SEE YOUR DEALER.

Excessive belt/

sheave clearance

Loose torque stop

Sticky clutch

• Inspect and adjust.

• SEE YOUR DEALER.

Engine doesn't turn

Seized engine

• SEE YOUR DEALER. Seizure is a

result of poor lubrication, inade-

quate fuel supply, broken parts or

improper cooling.

Hydrostatic lock

• Fuel may have entered the crankcase

while the vehicle was standing or

being transported. SEE YOUR

DEALER to correct the cause. Drain

plug(s) are located on the lower

crankcase for emergency draining.

Engine doesn't start

(electric start mod-

els)

Wire connections

Poor fuel

• SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

• Replace with fresh winter fuel.

Not enough fuel get- • SEE YOUR DEALER.

ting to engine

104

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Engine turns but fails Faulty ignition

to start

• Install new spark plug(s). If engine

still fails to start, check for spark. If

there's no spark, SEE YOUR

DEALER.

No fuel to engine

• Make sure the fuel valve is on.

• Use the choke.

• Make sure fuel tank contains fuel.

• Ice may be in fuel line, filter or

pump. Add isopropyl alcohol to fuel

system. On the standard POLARIS

carburetor, the choke will not func-

tion with the throttle depressed.

Flooded engine (too • Hold throttle open, crank engine

much choke used)

several times (may be necessary to

change plug(s).

Poor engine com-

pression

• Mixture is too lean. A main jet that

is too small will cause seizure result-

ing in loss of power. This indicates a

major engine problem that must be

repaired before operating. SEE

YOUR DEALER.

Engine lacks power

Fouled or defective

spark plug(s)

• Replace the plug(s).

Fuel filter (loss of

high RPM power)

• Check fuel filter flow. Disconnect

hose and drain 1/2 cup. Fuel flow

should be steady and encompass the

entire diameter of fuel line. If not,

replace filter.

Incorrect clutching

• SEE YOUR DEALER.

Carburetor and fuel

pump

Engine continually

backfires

Faulty plug(s)

• Change plug(s).

Carburetor / Fuel

System

• Dirt or ice may be in the fuel system

(add deicer to non-ethanol fuel at all

times to prevent icing).

Incorrect throttle

freeplay or faulty

switch

• SEE YOUR DEALER.

105

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TROUBLESHOOTING

Rear Suspension Troubleshooting

Problem

Solution

Rear suspension bot-

toms too easily

• Adjust torsion spring preload to achieve proper static sag

(see page 32).

• Change torsion spring to stiffer optional spring (see your

dealer).

• Revalve rear track shock (see your dealer).

• Rotate RRSS to higher position (see page 36).

Rides too stiff in rear • Check for binding suspension shafts and grease all pivot

points.

• Adjust torsion spring preload to achieve proper static sag

(see page 32).

• Change torsion spring to softer optional spring (see your

dealer).

• Check track tension (see page 88).

• Rotate RRSS to lower position (see page 36).

Machine darts from

side to side

• Check ski alignment (see page 92).

• Make sure spindles and all steering components turn freely.

• Check for excessive play in steering assembly (see your

dealer).

• Ensure skags are straight on skis.

• Set static sag (see page 32).

• Check rail slide/replace if worn (see page 94).

• Install Accu-Trak dual skags (see your dealer).

Front end pushes

Steering is heavy

• Check for worn skags.

• Check for binding front suspension shafts and steering

components, grease all pivot points (elevate front of

machine).

• Set static sag (see page 32).

• Install single skag (see your dealer).

• Increase IFS preload (if equipped) (see page 28).

• Rotate RRSS to higher position (see page 36).

• Make sure spindles and all steering components turn freely.

• Check ski alignment (see page 92).

• Check skags and skis for damage.

• Set static sag (see page 32).

106

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TROUBLESHOOTING

Drive Belt Troubleshooting

Belt Wear/Burn Diagnosis

Solutions

Causes

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

and slow speed (8000

RPM/10 MPH)

• Lower the gear ratio. Reduce RPM. Avoid riding in

high ambient temperatures. Check for snow ingestion.

Ice and snow build-up

• Warm the engine at least five minutes. Take the drive

belt off the machine in extremely cold weather and

warm it up. Break machine loose from the snow.

between track and tunnel

Poor engine performance • Check for carburetor and choke synchronization, fouled

plugs, debris in the carburetor(s) and water, ice or dirt

in the fuel tank or fuel line.

Loading machines onto

trailers

• Skis may gouge into trailers and prevent the drivetrain

from 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.

Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.

ment

107

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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, modifi-

cations and tips on snowmobile maintenance, which may supersede informa-

tion 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 fol-

lowing information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

Use the page provided near the front of your Owner's Manual to record the

identification numbers of your snowmobile and its engine.

POLARIS Customer Service

United States: 1-888-704-5290

Canada: 1-204-925-7100

108

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WARRANTY

Service and Warranty Information

POLARIS Anti-Theft System

The POLARIS anti-theft system (PATS) monitoring program is designed to aid

owners of registered snowmobiles in recovery of stolen machines.

Administration

1. POLARIS snowmobile owner reports theft.

A. In addition to notifying the proper law enforcement officials, the owner

must call POLARIS Customer Service.

B. Owners must provide their name, address, telephone number and

the model and serial number of stolen machines.

2. POLARIS warranty will provide all dealerships with a monthly

updated list of all stolen units to further monitor thefts.

3. POLARIS warranty will aid in notifying the proper owner when a

unit is recovered.

109

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WARRANTY

Limited Warranty

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR

LIMITED WARRANTY on all components of the POLARIS snowmobile against

defects in material or workmanship. This warranty covers the parts and labor charges for

repair or replacement of defective parts that are covered by this warranty. The warranty

begins on the date of purchase. This warranty is transferable to another consumer, dur-

ing the warranty 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.

110

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WARRANTY

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship.

The warranty does not cover accidental damage, normal wear and tear, abuse or

improper handling. The warranty also does not cover any snowmobile that has been

structurally altered, neglected, improperly maintained, used for racing or used for pur-

poses other than for which it was manufactured. The warranty does not cover any dam-

ages that occur during trailer transit or as a result of unauthorized service or parts. In

addition, this warranty does not cover physical damage to paint or finish, stress cracks,

tearing or puncturing of upholstery material, corrosion or defects in parts, components

or the snowmobile due to fire, explosions or any other cause beyond POLARIS' control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the snowmobile.

The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive

option, repair or replacement of any defective materials, or components or products.

THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES

AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS

SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARIS-

ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CON-

SEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT

FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY

FAILED OF ITS ESSENTIAL PURPOSE. Some states do not permit the exclusion 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.

111

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WARRANTY

Warranty Coverage and Exclusions

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

Promotional Warranties

Promotional warranties are sometimes offered by POLARIS. These warranties can be,

but are not limited to:

•

Two-year extended engine coverage

Two-year powertrain coverage

Extended service contract

If you selected any type of extended warranty coverage as part of a POLARIS retail pro-

gram, please contact any authorized POLARIS dealer for additional information.

How to Obtain Warranty Service

If your snowmobile requires warranty service, you must take it to a POLARIS dealer

authorized to repair POLARIS snowmobiles. When requesting warranty service you

must present your copy of the Warranty Registration form to the dealer. (The cost of

transportation to and from the dealer is YOUR responsibility). POLARIS recommends

that you use your original selling dealer; however, you may use any POLARIS Servicing

Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Your dealer will contact the

appropriate personnel at POLARIS if additional assistance is needed.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-

ommend the use of POLARIS engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

112

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WARRANTY

Warranty Coverage and Exclusions

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 vehi-

cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con-

sumer sign the PDI form prior to delivery may void the warranty. Failure to provide

proof of required periodic maintenance upon request may result in denial of warranty

coverage. Use of the recommended POLARIS products for lubrication and maintenance

as directed by the Owner's manual is highly recommended. Should a failure occur dur-

ing 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

113

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WARRANTY

Warranty Coverage and Exclusions

Conditions and Exclusions

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

Meals

Towing charges

Mileage

Rentals/Loss of product use

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

114

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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 Bulletins.

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, War-

ranty 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 perform the warranty repair.

115

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WARRANTY

Exported Vehicles

How to Get Service

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 importa-

tion rules vary considerably from country to country. You may be required to present

documentation of your move to POLARIS Industries in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS Industries

in order to register your vehicle in your new country. You should warranty register your

vehicle at a local POLARIS dealer in your new country immediately after you move to

continue your warranty coverage and to ensure that you receive safety information and

notices regarding your vehicle.

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. You

must nonetheless warranty register your vehicle under your name and address with a

local POLARIS dealer in your country to ensure that you receive safety information and

notices regarding your vehicle.

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, other than safety bulletins. (Vehicles reg-

istered to Government officials or military personnel on assignment outside of the

country where the vehicle was purchased will continue to be covered by the basic war-

ranty.)

For questions call POLARIS Customer Assistance (see page 108).

116

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited war-

ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur-

chased, this emissions-certified vehicle is designed, built and equipped so it conforms

with applicable U.S. Environmental Protection Agency emission regulations. POLARIS

warrants that the vehicle is free from defects in materials and workmanship that would

cause it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 200 hours of engine operation, 4000 kilo-

meters (2485 miles) of vehicle travel, or 30 calendar months from the date of purchase,

whichever comes first.

This emissions limited warranty covers components whose failure increases the vehi-

cle’s regulated emissions, and it covers components of systems whose only purpose is to

control emissions. Repairing or replacing other components not covered by this war-

ranty is the responsibility of the vehicle owner. This emissions limited warranty does not

cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emis-

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emis-

sions:

•

Fuel Tank

•

Vacuum Control Diaphragms*

Control Cables*

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of POLARIS, repair or replacement of any defective materials, components or

products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND

SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-

POSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES 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 if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or when the vehicle has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. POLARIS may deny warranty claims for failures that have been caused

by the owner’s or operator’s improper maintenance or use, by accidents for which

POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your vehicle. POLARIS recommends that you contact an

authorized POLARIS dealer to perform any service that may be necessary for your vehi-

cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential

violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer

reduces the effectiveness of the vehicle's emission controls. Tampering with emission

controls is prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please

contact the POLARIS Warranty Department at 1-888-704-5290.

118

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MAINTENANCE LOG

Present this section of your manual to your dealer each time your snow-

mobile is serviced. This will provide you and future owners with an

accurate log of maintenance and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

121

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 39

Adjustable Headlights . . . . . . . . . . . 27

Air Pollution . . . . . . . . . . . . . . . . . . . 5

Altitude Setting . . . . . . . . . . . . . . . . 59

Avalanches. . . . . . . . . . . . . . . . . . . . 13

Clutch System . . . . . . . . . . . . . . . 82-85

Clutching

550 IQ SHIFT . . . . . . . . . . . . . . 99

550 IQ 136/LXT . . . . . . . . . . . 101

Cold Weather Drive-Away . . . . . . . . 17

Controls and Linkage . . . . . . . . . . . . 95

Coolant . . . . . . . . . . . . . . . . . . . . . . . 73

Cooling System . . . . . . . . . . . . . . . . . 73

Customer Service . . . . . . . . . . . . . . 108

Bearings. . . . . . . . . . . . . . . . . . . . . . 96

Before Starting the Engine. . . . . . . . 41

Bleeding the Brake System . . . . . . . 79

Brake Components. . . . . . . . . . . . . . 77

Brake Fluid . . . . . . . . . . . . . . . . . . . 78

Brake Inspection . . . . . . . . . . . . . . . 77

Brake Lever Travel . . . . . . . . . . 42, 77

Brake System Bleeding . . . . . . . . . . 79

Brakelight Replacement. . . . . . . . . . 81

Brakes . . . . . . . . . . . . . . . . . . 42, 77-79

Break-In Period . . . . . . . . . . . . . . 48-49

Disabled Operators . . . . . . . . . . . . . . 10

Drive Belt . . . . . . . . . . . . . . . . . . 17, 84

Drive Belt Adjustment . . . . . . . . . . . 85

Drive Belt Break-In. . . . . . . . . . . . . . 49

Drive Belt Condition. . . . . . . . . . . . . 83

Drive Belt Deflection . . . . . . . . . . . . 85

Drive Belt Installation. . . . . . . . . . . . 84

Drive Belt Removal. . . . . . . . . . . . . . 83

Drive Belt Troubleshooting. . . . . . . 107

Drive Chain Tension . . . . . . . . . . . . . 76

Driver Awareness . . . . . . . . . . . . . . . 12

Driveshaft Bearing . . . . . . . . . . . . . . 67

Driving Downhill . . . . . . . . . . . . . . . 15

Driving in Hilly Terrain . . . . . . . . . . 16

Driving on Slippery Surfaces . . . . . . 14

Driving Responsibly . . . . . . . . . . . . . 19

Carbide Skags . . . . . . . . . . . . . . . . . 37

Carburetion . . . . . . . . . . . . . . . . . 54-55

Carburetor . . . . . . . . . . . . . . . . . . . . 74

Carburetor Adjustments. . . . . . . . . . 74

Carburetor Jetting

550 IQ SHIFT . . . . . . . . . . . . . 99

550 IQ 136/LXT . . . . . . . . . . 101

Carburetor Protection. . . . . . . . . . . . 96

Carburetor Water/Sediment Trap . . 75

Cargo Bag . . . . . . . . . . . . . . . . . . . . 27

Cargo Overload . . . . . . . . . . . . . . . . 10

Chaincase Oil. . . . . . . . . . . . . . . . 68-69

Choke. . . . . . . . . . . . . . . . . . . . . . . . 67

Choke Cable. . . . . . . . . . . . . . . . . . . 67

Choke Operation . . . . . . . . . . . . . . . 47

Cleaning and Preservation. . . . . . . . 95

Clutch Alignment Offset . . . . . . . . . 82

Clutch and Drive System. . . . . . . . . 96

Clutch Cover Warning. . . . . . . . . . . 21

Clutch Safety . . . . . . . . . . . . . . . . . . 17

Electrical Connections . . . . . . . . . . . 97

Emissions Limited Warranty. . 117-118

Engine Break-In . . . . . . . . . . . . . . . . 48

Engine Protection . . . . . . . . . . . . . . . 96

Engine Safety . . . . . . . . . . . . . . . . . . . 8

Engine Stop Switch. . . . . . . . . . . . . . 56

Environment . . . . . . . . . . . . . . . . . . . . 5

Exhaust System . . . . . . . . . . . . . . . . . 73

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INDEX

Front Rear Scissor Stop . . . . . . . . . . 34

Front Suspension Adjustments . . 28-29

Front To Rear Coupling . . . . . . . . . . 34

FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fuel . . . . . . . . . . . . . . . . . . . . . . . 51-52

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 73

Fuel Pump. . . . . . . . . . . . . . . . . . . . . 72

Fuel System Deicers . . . . . . . . . . . . . 52

Fuel Valve. . . . . . . . . . . . . . . . . . . . . 52

Maintenance . . . . . . . . . . . . . . . . . . . 17

Maintenance Interval Table . . . . 63-65

Maintenance Log . . . . . . . . . . 119-121

Maintenance Program. . . . . . . . . . . . 62

Maneuverability . . . . . . . . . . . . . . . . 17

No Passenger Warning. . . . . . . . . . . 22

Noise. . . . . . . . . . . . . . . . . . . . . . . . . . 5

Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 72

Oil Injection System. . . . . . . . . . . . . 49

Oil Level. . . . . . . . . . . . . . . . . . . . . . 53

Oil Lines. . . . . . . . . . . . . . . . . . . . . . 72

Oil Recommendations . . . . . . . . . . . 49

Operation Warning. . . . . . . . . . . 23-24

Operator Safety. . . . . . . . . . . . . . . 6-20

Grab Handle Adjustment . . . . . . . . . 27

Handlebar Adjustments. . . . . . . . . . . 38

Headlight Adjustment. . . . . . . . . . . . 27

Headlight Bulb Installation. . . . . . . . 80

Headlight Bulb Removal . . . . . . . . . 80

Hood Latches . . . . . . . . . . . . . . . . . . 45

Park Brake Lever Lock. . . . . . . . . . . 43

Passenger Warning. . . . . . . . . . . . . . 22

Polaris Products . . . . . . . . . . . . . . . 102

Preload, IFS Shock Spring . . . . . . . . 29

Pre-Ride Checklist . . . . . . . . . . . . . . 40

Pre-Ride Suspension Inspection. . . . 45

Ice and Snow Build-up . . . . . . . . . . . 14

IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

IFS Adjustment Options . . . . . . . . . . 28

IFS Components . . . . . . . . . . . . . . . . 28

Inadequate Snow Conditions . . . . . . 18

Intake Filters . . . . . . . . . . . . . . . . . . . 72

Intake Silencer . . . . . . . . . . . . . . . . . 17

Rail Slide Wear . . . . . . . . . . . . . . . . 94

Rear Rear Scissor Stop. . . . . . . . . . . 35

Rear Suspension Adjustments . . 30-36

Rear To Front Coupling . . . . . . . . . . 35

Recoil Rope . . . . . . . . . . . . . . . . . . . 45

Recommended Maintenance . . . . . . . 7

Registration, Warranty . . . . . . . . . . 110

Reverse . . . . . . . . . . . . . . . . . . . . 58-59

Reverse Warning . . . . . . . . . . . . . . . 23

Jetting Guidelines . . . . . . . . . . . . . . . 55

Lights . . . . . . . . . . . . . . . . . . . . . 80-81

Limiter Strap Position. . . . . . . . . . . . 33

Low Oil Indicator Light . . . . . . . . . . 53

Lubrication . . . . . . . . . . . . . . . . . 66-69

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INDEX

Rider Capacity . . . . . . . . . . . . . . . . . 11

Riding Apparel. . . . . . . . . . . . . . . . . . 9

Riding Position . . . . . . . . . . . . . . . . . 8

RRSS . . . . . . . . . . . . . . . . . . . . . . . . 35

Taillight/Brakelight Replacement . . . 81

Throttle Cable . . . . . . . . . . . . . . . . . . 67

Throttle Lever . . . . . . . . . . . . . . . 41, 57

Throttle Safety Switch. . . . . . . . . 41, 56

Torque Stop. . . . . . . . . . . . . . . . . . . . 85

Torsion Spring Preload, IQ . . . . . . . . 33

Towing . . . . . . . . . . . . . . . . . . . . . . . 60

Track . . . . . . . . . . . . . . . . . . . . . . . . . 44

Track Alignment . . . . . . . . . . . . . . . . 90

Track Care for Storage . . . . . . . . . . . 97

Track Inspection . . . . . . . . . . . . . . . . 86

Track Lubrication . . . . . . . . . . . . . . . 87

Track Maintenance . . . . . . . . . . . 86-90

Track Safety . . . . . . . . . . . . . . . . . . . . 8

Track Tension . . . . . . . . . . . . . . . 31, 88

Track Warm-Up . . . . . . . . . . . . . . . . 50

Track Warning . . . . . . . . . . . . . . . . . 22

Traction Products . . . . . . . . . . . . . . . 37

Transporting the Snowmobile. . . . . . 97

Troubleshooting, Drive Belt . . . . . . 107

Troubleshooting, Engine. . . . . 103-105

Troubleshooting, Rear Suspension . 106

Tune-Up . . . . . . . . . . . . . . . . . . . . . . 95

Safety Decals . . . . . . . . . . . . . . . . 21-24

Safety Symbols . . . . . . . . . . . . . . . . . 6

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Sediment Trap . . . . . . . . . . . . . . . . . 75

Signal Words . . . . . . . . . . . . . . . . . . . 6

Ski Alignment . . . . . . . . . . . . . . . . . 92

Ski Pressure . . . . . . . . . . . . . . . . . . . 33

Ski Skags . . . . . . . . . . . . . . . . . . . . . 93

Slide Rail and Track Cooling . . . . . 50

Snow Conditions . . . . . . . . . . . . . . . 18

Spark Plug . . . . . . . . . . . . . . . . . . . . 71

Spark Plug Condition. . . . . . . . . . . . 71

Spark Plugs . . . . . . . . . . . . . . . . . 70-71

Specifications. . . . . . . . . . . . . . . . . . 98

Speed . . . . . . . . . . . . . . . . . . . . . . . . 11

Spring Preload . . . . . . . . . . . . . . . . . 32

Spring Preload, IFS Shock. . . . . . . . 29

Spring Preload, Rear, IQ . . . . . . . . . 32

Starting the Engine . . . . . . . . . . . . . 47

Steering Inspection/Adjustment. . . . 91

Steering System . . . . . . . . . . . 44, 91-94

Stopping, Emergency. . . . . . . . . . . . 48

Storage, Daily . . . . . . . . . . . . . . . . . 95

Storage, Extended . . . . . . . . . . . . 95-97

Survival Preparation . . . . . . . . . . . . 10

Suspension Coupling, IQ. . . . . . . 34-35

Suspension Inspection, Pre-Ride . . . 45

Suspension Performance Tips . . . . . 31

Suspension, Front, Lubrication . . . . 66

Suspension, Rear, Lubrication. . . . . 66

Vehicle Identification Numbers . . . . . 4

Wear Strips . . . . . . . . . . . . . . . . . . . . 37

Weight Transfer . . . . . . . . . . . . . . . . 36

Windchill. . . . . . . . . . . . . . . . . . . . . . 20

Windchill/Temperature Charts . . . . . 20

124

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