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WARNING
Read, understand, and follow all of the instructions
and safety precautions in this manual and on all
product labels.
Failure to follow the safety precautions could result
in serious injury or death.
PROPOSITION 65
WARNING
Snowmobile engines discharge fuel
and exhaust, which contain chemicals
known to the State of California to
cause cancer and birth defects or other
reproductive harm, onto the snow on
which they operate. Keep this engine
properly tuned and avoid unnecessary
idling and spillage during fueling.
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 700/900 Fusion Owner’s Manual P/N 9919666
2
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . . . 58
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . 117
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 118
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . 132
Present this section of your manual to your dealer each time your
snowmobile is serviced. This will provide you and future owners with
an accurate log of maintenance and services performed on the
snowmobile.
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3
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INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when sold.
Some of the illustrations and photos used in this manual are general
representations. Your model may differ.
Follow the maintenance program outlined in this manual. Preventive
maintenance ensures that critical components of the snowmobile are
inspected by your dealer at specific mileage intervals.
You and your dealer must complete the registration form included with
your snowmobile and forward it to us. This completed form is
necessary to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
4
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INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may
not be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission
levels of two-stroke engines. We expect our efforts to lead to the
reduction of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
5
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INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile’s identification numbers 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.
1
Vehicle Model Number:
Tunnel VIN (1)(lower right side of the tunnel):
Engine Serial Number (on recoil housing):
Key Number:
6
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
7
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SAFETY
Operator Safety
Follow the recommended maintenance program outlined beginning on
page 78 of this manual to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific
mileage intervals.
WARNING
Driving a snowmobile requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving or
riding as a passenger. They will reduce your alertness and slow
your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra
caution to ensure operator safety. Make sure your snowmobile is
in excellent operating condition at all times. Always check major
and vital safety components before every ride.
All Polaris snowmobiles are designed and tested to provide safe
operation when used as directed. Failure of critical machine
components may result from operation with any modifications,
especially those that increase speed or power. DO NOT
MODIFY YOUR MACHINE. The snowmobile may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.
8
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation.
WARNING
Serious injuries may result if hands,
feet, or clothing become entangled in
the track. Be alert when riding, and
remain properly seated to stay clear
of the track.
Never hold the snowmobile up or
stand behind it while warming up the
track. A loose track or flying debris
could cause serious injury or death.
We recommend having your dealer
perform all track service and
alignment procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Turn off the
ignition, 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.
9
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SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under most conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING
Improper riding position may reduce control and could result in
serious injury or death. Always be properly seated and in position
to control your vehicle.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular telephone.
For added protection, carry the following items on your snowmobile at
all times:
SSpare Drive Belt
STow Rope
SFuel Deicer
STrail Map
SFirst Aid Kit
SExtra Set of Spark Plugs
SExtra Oil
SWinter Survival Kit
SOwner’s Manual
STool Kit
10
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SAFETY
Operator Safety
Riding Apparel
Be prepared, be warm and be
comfortable when riding. Be
aware of the weather
forecast, especially the
windchill, and dress
accordingly. See the chart
on page 20.
WARNING
Avoid wearing loose
clothing or long
scarves, which can
become entangled in
moving parts and
cause serious injury.
Always wear an
approved helmet and
eye protection.
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.
11
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SAFETY
Operator Safety
Rider Capacity
Your Polaris snowmobile is designed for a single rider only. Do not
carry a passenger.
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious
injury or death. Always reduce speed when driving at night or in
inclement weather.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the
trail ahead. Multiplying speed (MPH) by 1.5 will equal the
approximate number of feet per second your machine travels. If your
speed is 40 MPH, your machine is traveling about 60 feet per second.
If you look back for only two seconds, your machine will travel about
120 feet. If your speed is 60 MPH, your machine will travel about 180
feet 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
illuminated by the headlight.
12
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SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you’re snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or
highways. Steep embankments may also
hide your view. Always leave yourself a
way out.
Variances in snow depth and/or water
currents may result in uneven ice
thickness. You may drown if you break
through the ice. Avoid travelling on frozen bodies of water.
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.
13
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
S Take an avalanche class
S Travel with experienced people
S Travel on designated trails
S Make sure each person is equipped with
a shovel, probe and avalanche beacon.
You don’t have to be snowmobiling on a slope for an avalanche to
occur. Be aware that all of the snow is connected. You may be riding
on a flat slope or snow covered road, but if the snowpack above is
unstable enough you can trigger an avalanche on a steeper slope above
you. Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit either
the American Avalanche Association online at
www.americanavalancheassociation.org or the U.S. Forest Service
National Avalanche Center at www.avalanche.org.
14
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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.
NOTE: If your snowmobile is equipped with RIDER SELECT,
perform this check in both the full up and full down steering
positions.
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution.
Driving on ice or hard-packed snow reduces steering and braking
control, which may result in loss of control and serious injury or
death. Slow down and use extra caution when operating on
slippery surfaces.
Driving Downhill
When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep
the clutch engaged, allowing the engine’s compression to help slow the
machine and keep it from rolling freely downhill.
WARNING
When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.
15
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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.
16
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SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is
dynamically balanced before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the machine into motion, but always operate
within safety limits.
Maneuverability
While much control and maneuverability is achieved through the
steering system and skis, maximum control is achieved by the shifting
of your body weight. Maneuverability will change for lighter operators
or machines designed to carry a load.
17
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SAFETY
Operator Safety
Inadequate Snow Conditions
WARNING
Do not drive for prolonged periods on blacktop, gravel, or ice.
Doing so could cause irreversible track damage and lead to
serious injury.
Since snow provides the only lubrication for the power slide
suspension and, on liquid cooled models, cooling for the engine,
adequate snow cover is a requirement for operation of your machine.
Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine.
If the machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when
the throttle is opened, the snowmobile will be able to climb up and
over the snow.
CAUTION
When operating on icy surfaces or hard-packed snow, avoid
overheating the slide rail and track. Lack of lubrication and
cooling will cause overheating of the slide rail and track, resulting
in premature wear and failure. If frequently operating in low
cooling conditions, see your dealer for an optional wheel kit that
will reduce the wear from overheating.
18
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SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile
conditions may become dangerous if operators drive improperly. If
you’re new to snowmobiling, acquaint yourself with the machine and
with what it will and won’t do under various conditions. Even
seasoned drivers should spend some time getting the feel for a machine
before attempting ambitious maneuvers.
S A snowmobile depends on the rider’s body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
S Before allowing someone else use your snowmobile, know the ex-
tent of their operating skills. Check to see if they’ve taken a snow-
mobile safety course and have an operator’s certificate. For their
protection, as well as yours, make sure they take a snowmobile safe-
ty course. Everyone can benefit from the course.
S Don’t “jump” your snowmobile. Jumping may injure your back be-
cause of spinal compression. The seat and suspension of your snow-
mobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.
S Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
S 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 sur-
faces or when driving in darkness or other low visibility conditions.
Be aware of any snowmobile traffic around your vehicle. Drive de-
fensively to avoid accidents.
S Remove the key from the ignition when you leave the snowmobile
unattended.
19
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when
temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
in
Actual Thermometer Reading (°F)
MPH
40 35 30 25 20 15 10
5
0
-5 -10 -15 -20 -25 -30 -35 -40 -45
Equivalent Temperature (°F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63
Calm 40 35 30 25 20 15 10
5
0
5
36 31 25 19 13
7
3
1
10
15
20
25
30
35
40
45
50
55
60
34 27 21 15
32 25 19 13
30 24 17 11
9
6
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
0
4
-2
29 23 16
28 22 15
28 21 14
27 20 13
26 19 12
26 19 12
25 18 11
25 17 10
9
8
7
6
5
4
4
3
3
1
0
-1
-2
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
-8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
Frostbite in >>
30 min.
10 min.
5 min.
WIND CHILL CHART (°C)
Wind
Speed
in
Actual Thermometer Reading (°C)
KPH
5
2
-1
-4
-4
-7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Equivalent Temperature (°C)
Calm
8
5
3
2
1
0
2
0
-1
-
-7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
-7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57
16
24
32
40
48
56
64
72
80
88
96
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
Frostbite in >>
30 min.
10 min.
5 min.
20
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your
protection. Read and follow the instructions of the decals 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 provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found under the hood on the clutch cover:
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of
applicable liquid cooled models:
Do not open hot. Test or replace when changing
coolant. Press down and turn to release cap. 13 PSI
21
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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
The “NO PASSENGER” warning decal is on the console below the
steering post:
+
22
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SAFETY
Safety Decals and Locations
Reverse Warning
The reverse warning decal is located
on the console below the
windshield:
Reverse operation, even at low
speeds, may cause loss of control
resulting in serious injury or
death. To avoid loss of control,
always:
S Look behind before and while
backing up.
+
S Avoid sharp turns.
S Shift to or from reverse only when stopped.
S Apply throttle slowly.
NOTE: For more information, see Owner’s Manual.
If electric reverse:
S Machine stopped and engine at idle, push yellow button on LH
control to reverse. Flashing light on dash indicates reverse opera-
tion.
S Push button again to return to forward.
Operation Warning
The operation warning decal is
located on the console above the
storage compartments. See page 24
for the text.
+
23
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SAFETY
Safety Decals and Locations
Operation Warning
Operation Warning Decal:
S To avoid serious injury or death, read and understand all warnings
and the Owner’s Manual before operation. If the manual is missing,
contact a Polaris dealer for a replacement.
S This vehicle is capable of high speeds. Buried objects or uneven ter-
rain can cause loss of control. Reduce speed and use extreme cau-
tion when operating in unfamiliar terrain.
S Excessive speed, especially at night or with limited visibility, can re-
sult in insufficient time for you to react to terrain changes, to avoid
unexpected obstacles, or to stop safely.
S Never consume alcohol or drugs before or while operating this ve-
hicle.
S 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.
S Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
S This vehicle is designed for adult use only. Check local laws for age
requirements.
S 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.
S 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.
S 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.
S Repeated stops from high speed may cause fading or sudden loss of
braking ability.
S Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
S 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 oillevel whenrefueling.
24
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FEATURES
5
4
3
2
1
6
7
8
1. Hood
2. Headlight
3. Windshield
4. Handlebar
5. Seat
6. Snow Flap
7. Suspension
8. Track
9. Storage Compartment
10. Rear Bumper
11. Taillights
12. Nosepan
13. Front Bumper
14. Skis
9
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FEATURES
5
4
6
3
9
2
7
8
1
1. Fuel Filler Cap
2. Ignition Switch
3. Brake Lever
4. MFD Gauge
13
12
11
14
5. Headlight Adjuster
6. Engine Stop Switch
7. Throttle Control
8. Hood Hold Down Straps
9. Recoil Starter Handle
10. Headlight Dimmer Switch
11. Park Brake
12. Handlebar Grip Warmer
10
15
Switch
13. Thumbwarmer Switch
14. Electronic Reverse Button
15. MFD Control
26
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FEATURES
RIDER SELECT Adjustable Steering System
The RIDER SELECT adjustable steering system allows you to adjust
the handlebar position to fit your style of riding.
WARNING
Attempting to adjust the handlebar position while the snowmobile
is moving could result in loss of control and serious injury or
death. Always stop the snowmobile before attempting to adjust
the steering system.
1. Stop the snowmobile.
2. Press the release button and move
the handlebar forward or rearward to
the desired position.
Setting
Position
Riding Style
Comfort
1, 2
Pull the system rearward to one of the first
two positions for all-day trail riding comfort.
Control
Attack
3, 4, 5
6, 7
Move the system to one of the middle three
positions for improved handling and corner-
ing on the trails.
Push the system forward to one of the last
two positions for easy sitting-to-standing
transitions and maximum agility in rugged
terrain.
WARNING
Do not lubricate the RIDER SELECT mechanism. Doing so could
cause loss of control and result in serious injury or death. The
RIDER SELECT mechanism is lubricated for life at the factory.
WARNING
Some aftermarket accessories (including windshields and cargo
bags) may interfere with the handlebar. Such accessories could
limit your ability to steer the vehicle and/or may contact the brake
lever. This could lead to loss of control resulting in serious injury
or death. Always be sure that accessories do not contact the
handlebar or brake lever at any steering position and at any
RIDER SELECT position.
27
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FEATURES
Seat Storage Compartment
Open or close the storage
compartments with the key.
Adjustable Headlights
Adjust the headlight beam by
moving the adjuster to the left
(to lower the beam) or to the
right (to raise the beam).
Access Panel
The access panel (1) is provided
for cleaning debris from the
radiator.
1
28
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FEATURES
Detonation Elimination Technology (D.E.T.)
A detonation sensor monitors the engine and responds to detonation by
automatically reducing the engine timing and adding fuel. This results
in decreased engine RPM and performance.
DET Troubleshooting
Use this chart to determine causes and solutions for detonation. If
none of these conditions exists and the sensor remains activated, see
your Polaris dealer for diagnosis.
Possible Cause
Solution
Poor quality fuel
Replace with higher quality fuel
Do not modify the engine
Improper engine modifications
Effect of DET
The DET system prevents damage to the engine from detonation while
developing the maximum power of the engine safely. If the system
senses detonation beyond a preset limit, it retards ignition timing and
adds fuel to reduce the detonation and prevent engine damage.
When the detonation returns to a permissible level, the system will
return spark and fuel to normal, allowing the engine to run at rated
power levels.
Sensor Fail-Safe
The DET includes a sensor fail-safe system to prevent the engine from
damage if the sensor fails, becomes disconnected or is unable to detect
detonation. The rider will experience a loss in power. The sensor must
be reconnected or repaired to regain full power.
NOTE: The check engine light will flash six times if the sensor fails
or becomes disconnected.
29
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FEATURES
Instrumentation
MFD Component Identification
Item
2
1
1
2
3
4
5
6
7
8
Analog Gauge
Digital Gauge
Check Engine Indicator
Low Oil Indicator
High Temp Indicator
Brake Indicator
Reverse Indicator
High Beam Indicator
3
8
7
5
4
6
Digital Display Identification
Item
1
RPM or Speed
Altitude (if equipped)
Service Interval
1
2
2
3
Electrical System Voltage
Level
MAX - Maximum MPH/
KPH or RPM
MPH - Miles per hour
KPH - Kilometers per hour
RPM - Engine crankshaft
revolutions per minute
4
Air Temp (if equipped)
Engine Temp)
Degrees Celsius
Degrees Fahrenheit
5
6
Miles
5
7
6
Kilometers
4
3
Hours
Trip 1/Trip 2/Trip F
Service Label
Altitude Label
7
Fuel Level
30
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FEATURES
Instrumentation
MFD Settings
With the engine running, use the
MFD Control Switch (1) to set the
MFD display to your preference.
The rocker switch has a MODE
button (2) and a SET button (3).
1
Standard vs. Metric
The MFD will display either
standard or metric units of
2
measurement. While viewing a
screen that displays measurements
3
(MPH, KPH or temperatures), press and hold the MODE switch until
the unit of measurement changes (about 10 seconds).
Speedometer/Tachometer
The speedometer and tachometer can be viewed in either the analog or
the digital display. If the analog display is set to show speedometer
readings, the digital screen will automatically display the tachometer
(option 1). If the analog is set to show the tachometer, the digital
screen will show the speedometer (option 2).
To change preferences, press and hold the MODE button for three
seconds. When the button is released, the new setting becomes active
and screen colors change. See table below.
Option
Analog
Display
Digital
Display
Analog
Screen
Digital
Screen
1
2
Speed
RPM
Blue “mph”
Blue
Backlight
RPM
Speed
Red “X100rpm”
Red
Backlight
31
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FEATURES
Instrumentation
MFD Digital Display Programs
Press the MODE button to cycle through the three MFD programs:
Performance, Engine and History. Each program will remain in the
display until another is selected.
NOTE: The analog will always display either MPH or engine RPM
(whichever setting is selected) regardless of the display
program being viewed.
Performance Program
The Performance Program automatically displays either speed or
tachometer, whichever is opposite the analog display. See page 31. It
also displays electrical system voltage and fuel levels.
While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F and Clock settings.
Trip Settings
Trip 1 and Trip 2 are odometers used to
check fuel mileage or to keep track of
distance traveled.
1. To reset a trip odometer to zero,
enter the Trip 1 or Trip 2 display.
2. Press and hold the SET button for
two seconds.
Trip F automatically displays if the fuel
level is low. The fuel symbol and the
last fuel bar on the MFD gauge will
blink when the fuel level reaches 1/8th
tank. The Trip F odometer records
distance traveled until enough fuel is
added to raise the level above 1/4 tank.
The fuel symbol and the fuel bar will
continue to blink until the fuel level is
above 1/4 tank. The Trip F odometer
will automatically reset to zero after
refueling.
Odometer Setting
The odometer records the vehicle’s
total distance traveled since
manufacture. The odometer cannot be
reset.
32
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FEATURES
Instrumentation
MFD Digital Display Programs
Performance Program
Clock Setting
1. While in the CLOCK display, press
and hold the SET button for five
seconds.
2. When the hour starts flashing press
the SET switch once to advance one
hour, or press and hold the SET
button to advance the hour once
every 0.2 seconds.
3. Press the MODE button to save the hour and flash the minutes.
4. Set the minutes in the same manner.
5. When finished, press the MODE button to save the new setting.
NOTE: If the MODE button is not pressed within ten seconds, the
clock will automatically save the new entry.
Engine Program
The Engine Program automatically displays the engine coolant
temperature, engine hours, electrical system voltage level and fuel
level. On machines equipped with altimeter sensor and ambient air
temperature sensors, altitude and ambient air temperature will display
as additional screens in the engine program. Press the SET button to
display the ambient air temperature and altitude screens (if equipped).
Air Temperature (if equipped)
The MFD displays actual air temperature.
Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.
33
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FEATURES
Instrumentation
MFD Digital Display Programs
Altitude (if equipped)
The rider can calibrate the altimeter for
current atmospheric conditions. Altimeter
accuracy will be +/--300 ft. (91 m) after
adjustment.
NOTE: Press and hold the MODE switch
for ten seconds to switch
between standard and metric units of measurement. When
“ALt” displays, the program is in the metric mode.
1. Enter the Engine Program and select the altimeter display.
2. Press and hold the SET button for five seconds.
3. When the digits begin to flash, press the SET button once to
advance 50 feet (15 m), or press and hold the button to advance
100 ft. (30 m) every 0.1 seconds. Adjust the altitude display to
within 50 ft. (15 m) of current altitude.
NOTE: The gauge reads barometric pressure and allows the rider to
compensate for daily fluctuations in air pressure. The gauge
can adjust the displayed altitude to +/-- 1300 ft. (396 m) from
the preset value. It will adjust up to +1300 ft. (396 m) above
the calibrated altitude. Once the +1300 ft. (396 m) offset has
been reached, the next adjustment is --1300 ft. (396 m) from
the calibrated altitude, and 50 ft. (15 m) will be added to the
altitude each time the SET button is pressed.
4. Press the MODE button to hold the reading at the adjusted value. If
the it’s not pressed within five seconds, the gauge will
automatically save the new setting.
Hour Meter
The hour meter records the total hours of
engine operation since manufacture. This
meter cannot be reset.
Engine Temperature
A thermometer measures water temperature,
giving an indication of engine temperature.
34
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
The History Program automatically displays electrical system voltage
level and fuel level.
While in the History mode, press the SET button to view maximum
vehicle speed, maximum engine rpm or the current service interval
setting. The gauge automatically logs the maximum speed and engine
rpm even if the History Program is not currently displayed.
The History Program will display the history of the Maximum Speed,
Maximum RPM and Service Interval settings.
Maximum Speed/RPM Reset
While in either the MAX MPH or the
MAX RPM mode, press and hold the
SET button for three seconds to reset
the recorded maximum values for both
MPH and RPM. Both of these values
are reset at the same time. Reset the
MAX MPH/RPM values before each
run to obtain accurate readings.
NOTE: Due to electrical noise, the
MFD may occasionally
display MAX MPH/RPM
values that are not
representative of actual
values.
35
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FEATURES
Instrumentation
MFD Digital Display Programs
Service Interval Reminder
The gauge logs the number of engine
hours between service reminders.
When the logged hours reaches the
designated service interval (set by the
user), the gauge provides a reminder
that service is due. “SErVCE” will
flash in the odometer area and “ENG”
will flash in the icon area for five
seconds each time the vehicle is
started until the service reminder is reset.
To reset the reminder at the existing interval:
1. Enter the service interval screen.
2. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.
3. When the display stops flashing, release the button. The service
interval has been reset.
To reset the reminder at a new interval:
1. Enter the service interval screen.
2. Press and hold the SET button for five seconds, until the hours
begin to flash.
3. Immediately release the button.
4. Press the button again up to five times to advance the reminder in
50-hour increments.
NOTE: The maximum interval is 250 hours.
To disable the service interval reminder, press the SET button once
after reaching 250 hours on the display. The gauge will display
“OFF”.
36
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FEATURES
Instrumentation
MFD Battery Replacement
If the clock function of the MFD isn’t
working properly, replace the battery.
Replacement batteries are available
from your dealer.
A
1. Remove the plenum from the
underside of the hood.
2. Locate the black battery
compartment (A). It has a red
wire and a brown wire with a
white stripe. It’s located about
three inches down the main
harness from the point where the
harness connects to the MFD.
B
3. Cut the plastic cable tie (B) from
the outside of the compartment.
C
4. Carefully cut the bottom of the
compartment (opposite the wires)
to separate the heat-sealed seams.
Squeeze the corners of the compartment inward so the battery (C)
is visible.
NOTE: Note the orientation of the battery before removing it. An
incorrectly installed battery will not maintain the clock.
5. Using needle-nose pliers, grasp the battery and rotate it slightly so
the leading edge of the battery is raised slightly away from the
battery holder. Pull the battery out gently.
NOTE: The battery will not come out of the holder unless the leading
edge of the battery is raised. Hold the battery compartment,
not the wires, while removing the battery. Pulling on the
wires will separate them from the battery holder.
6. Install a new battery with fingers only.
7. Seal the end of the battery compartment using high strength
double-sided tape between the two compartment halves or high
strength single-sided tape around the outside of the compartment.
8. Make sure the taped seam of the compartment faces the downward
side of the wire harness.
9. Install a cable tie to secure the compartment to the wire harness in
the same location where the previous cable tie was located. Make
sure the battery wires are not stretched tight.
37
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FEATURES
Instrumentation
Gauge Cleaning
1. Wipe the gauge face as needed using a clean cloth and a mild soap
and water solution. Wipe dry with clean, soft cloth.
2. Clean the back side of the gauge using a clean cloth and a mild
soap and water solution. Do not remove the electrical connectors
or protective rubber boot. Do not spray the back side of the gauge
or the wire harness with a pressure washer or other water source.
CAUTION
To prevent damage to the lens, do not use alcohol for cleaning.
Do not allow chemicals or sprays to come into contact with the
lens. Immediately clean off any gasoline that splashes on the
gauge during refueling.
38
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THE PERFECT FIT
IQ Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight,
vehicle speed, riding style, and trail conditions. We recommend
starting with factory settings and then customizing each adjustment
individually to suit rider preference. The machine should be
methodically tested, one change at a time, under the same conditions
(trail and snow conditions, vehicle speed, riding position, etc.) after
each adjustment until the best ride is achieved.
IFS Components
1. Skis
2. Front shocks and springs
3. Rod ends
4. Upper control arms
5. Lower control arms
IFS Adjustment Options
S Front shock spring preload
S Optional springs
5
S Optional shock valving (if
equipped with RydeFX shocks)
S Toe (ski alignment) (see page 110)
1
S Camber (see your dealer)
39
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THE PERFECT FIT
IQ Front Suspension Adjustments
WARNING
Always verify ski alignment before making adjustments to the
IFS. See page 110 to check alignment. If the skis are misaligned,
see your dealer, as the camber adjustment may also be affected.
The tension at which the shock coil spring is set is called spring
preload. For the best ride, the spring preload should be set as low as
possible to use the full travel of the ski shock, with occasional light
bottoming. To determine if your machine is using full travel of the ski
shock, push the jounce bumper down as far as it will go on the shock
rod and test ride the machine. The bumper will move up on the rod in
direct relation to the amount of travel. If the shock travel is full, the
bumper will be seated at the top of the shock.
Shock Absorber Components
1. Retainer
1
2. Jounce Bumper (RydeFX only)
3. Shock Rod
4. Body
5. Threaded Spring Preload Adjuster Nut
2
4
5
40
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THE PERFECT FIT
Front Suspension Adjustments
IQ Front Shock Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing spring
preload will decrease ski-to-ground
pressure. When adjusting, be sure the
springs on both the left and right sides of
the machine are at the same adjustment.
B
A
A = Low preload
B = High preload
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
rear suspension.
Decreasing the spring preload too much
may allow the upper spring retainer to fall
off.
NOTE: Always leave at least one
thread showing above the nut.
1. Grasp the spring and turn it to the left to increase preload.
2. Turn the spring to the right to decrease preload.
41
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THE PERFECT FIT
IQ Front Suspension Adjustments
Shock Valving
RydeFX shocks can be revalved if spring preload alone isn’t sufficient
and further adjustment is desired to control suspension stiffness.
WARNING
Changing shock valving on RydeFX shocks requires special
tools and a sound knowledge of mechanical theory, tool use, and
shop procedures to perform the work safely and correctly.
Shocks contain high-pressure nitrogen gas. Use extreme caution
when handling high-pressure service equipment. We recommend
that this work be performed by a Polaris dealer.
Front Springs
The front springs can be changed if spring preload alone isn’t sufficient
and further adjustment is desired to control suspension stiffness. See
your Polaris dealer for more information.
42
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and
deliver excellent performance for a given set of conditions. However,
all suspension designs and adjustments involve a compromise, or
trade-off. For example, a suspension set up for 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.
Make adjustments to one area at a time so you can evaluate the change.
For further assistance, see your dealer.
Suspension Performance Tips
S Rider weight usually determines the position at which the spring pre-
load should be set. However, this may vary with riding style. With
a little experimentation, each rider can find a preferred setup. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
S In deep snow, a new slider will offer improved performance over
worn slider. It can also improve top speed.
S When riding on ice or hard-packed snow, adding a set of bogie
wheels to the rail may enhance the machine’s performance. Bogie
wheel kits are available from your dealer.
S Polaris offers track kits for improved flotation in deep snow. See
your dealer for assistance.
NOTE: Keep the suspension pivot points lubricated. This will reduce
moisture and rust build-up and ensure proper function of the
suspension components. Grease rear suspension pivots
before adjusting the rear suspension. Refer to Suspension
Maintenance beginning on page 112.
43
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the IQ 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 extension.
X
NOTE: 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 distance between the
ground and the rear bumper at the
exact location used for measurement
X. This is measurement Y.
Y
To determine sag, commonly referred to as ride-in, subtract
measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion
spring preload cams located on the rear torque arm. Use the illustration
for reference. The ideal amount of Sag for the IQ rear suspension is
two inches (X-Y=2).
If the rear suspension rides in less than one inch or more than three
inches with the torsion spring preload cams at their maximum range of
adjustment, optional torsion springs (softer or stiffer, respectively) may
be required. This is only an initial setup, and final spring preload may
vary based on rider preference and riding conditions.
44
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Torsion Spring Tension
To adjust rear torsion spring tension, rotate the three-position cam
using the engine spark plug tool. Different rate torsion springs are
available if a firmer ride is desired. See your dealer for more
information.
1. Soft Tension
2. Medium tension
3. Firm tension
3
2
1
Rear Shocks
Polaris Position Sensitive Shock
There are no external adjustments on the Polaris position sensitive
(PPS) shock.
45
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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
independence between the movement of the front torque arm and the
rear torque arm.
When hitting a bump, the front torque arm starts to compress. The
FRSS links that movement to the rear torque arm, causing it to
compress and raise the rear suspension up as one, allowing the
suspension to hit the bump only once and eliminating kickback.
The factory setting is usually adequate for all riders and conditions.
46
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THE PERFECT FIT
IQ Rear Suspension Adjustments
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
independent movement between the rear torque and the front torque
arm.
Adjusting the RRSS either allows more weight to transfer to the rear
for more traction, or allows less weight to transfer to the rear, resulting
in improved cornering performance. An adjustment dot is located on
the RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop (RRSS) - Attributes
Moving the RRSS to a higher position will have the following effects
on the suspension:
S Reduced weight transfer.
S Improved chatter bump ride.
S Improved cornering performance.
47
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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
(RRSS). The factory setting (1) is the
best for most trail riding conditions.
1
To decrease weight transfer under
acceleration (for improved cornering),
rotate the RRSS to a higher position with
the scissor stop tool (2) located in your
2
tool kit.
H
H = High
L
L
L = Low
M = Medium
M
To increase weight transfer or ski lift during
acceleration, rotate the RRSS to a lower
position.
NOTE: Your dealer can help you with initial
setup and additional setup
instructions to help you achieve
your optimum ride.
48
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
The M-10 suspension has been designed to be very sensitive to rider
weight. Changes in rider weight of 25 lbs. (11 kg) or more might
require appropriate changes in settings. The following information has
been compiled to assist you in tuning your M-10 suspension to its
maximum potential and achieve the best possible ride. Please take the
time to read and understand all the possible adjustments available with
this suspension.
Static Sag and Ride Height Settings
Static sag describes the difference in height of the rear bumper from the
suspension’s fully extended position to its loaded height, with the rider
seated on the snowmobile. Too much sag will result in bottoming, and
too little sag will result in reduced rider comfort.
Sag is used to control ride quality and rebound travel. On this
suspension, sag is controlled by two settings, the full range adjuster
(FRA) position and the rear spring preload.
1. To check sag, raise the rear bumper until the suspension is fully
extended (the rear shock will not extend any further). Measure the
distance from the ground to the bottom of the bumper (dimension
X) as shown in the illustration. Record the measurement.
2. Have the rider sit on the snowmobile and bounce up and down on
the seat a few times to set in the suspension. While the rider
remains seated, measure the distance from the ground to the top of
the bumper (dimension Y) and record it.
3. Subtract Y from X and you will have the SAG setting (X - Y = sag
setting. Example: 21 - 17 = 4). The correct amount of SAG for
the FAST M-10 rear suspension is 3-4 inches (8-10 cm).
If the measured sag is incorrect, adjust the FRA position and rear
spring preload. See pages 50--51.
X
Y
49
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
FRA Position
The FRA setting is the primary rear suspension adjustment. It will have
the MOST effect on the rear suspension performance. To adjust the
FRA:
1. Refer to the initial set-up reference chart (located under the hood of
your snowmobile and on page 53) to determine the desired FRA
position.
2. To adjust, loosen the hex bolts (1) attaching the rear lower shock
cross shaft to the rail beam.
3. Using a 9/16” wrench, loosen the jam nuts (2) on the preload bolts.
4. Adjust the preload bolts (3) to the desired FRA position.
5. Tighten the jam nuts.
NOTE: Make sure the preload bolt contacts the slide block before
tightening the jam nut.
6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).
NOTE: When the M-10 suspension is new, it will take from 25 to 200
miles (40-300 km)to properly break in the springs and
shocks, at which time the suspension will be softer and may
require FRA re-adjustment.
1
3
2
50
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
Rear Spring Preload
If FRA position alone does not allow the setup of the proper amount of
sag, the center retainer of the rear track shock can be replaced with
optional retainers to adjust the preload and change the sag. See your
Polaris dealer for assistance.
OPTIONAL RETAINERS
Retainer Insert
Part Number
Retainer Part
Number
Preload
Sag
5135077
(standard on
M10-128)
Least
Most
5436109
5134923
Middle
Most
Middle
Least
5135080
(standard on
M10-136)
NOTE: Whenever ordering any of the retainers listed in the chart,
always order the retainer insert as well. The insert is not
removeable once installed, so a new insert is needed when
installing a new retainer.
51
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
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 front
limiter strap and front arm mount.
4
3
1. Determine if the rider
prefers comfort or
control. Lean toward th
#4 setting for comfort
and toward the #3
setting for aggressive
riding.
2
1
2. For full hole
2
adjustments,
3
4
remove the 5/16”
nut and flat washers
from the lower
attachments of the
limiter straps and relocate
the straps to the desired position
(i.e. move from position 4 to 3). Replace the nut and washer.
Tighten securely.
3. For half-hole increments (such as 3/4), the limiter straps have slots
at the upper pinch bolt. These slots allow the bolts to be loosened
(rather than removed) for half--step adjustments. Re--tighten the
pinch bolts.
52
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Ski Pressure
4. There are also two
front arm mounting
2
holes in the slide rail
that can adjust ski
pressure. The lower
hole (1) increases ski
pressure while the upper hole
(2) decreases ski pressure.
NOTE: By design, the BIASED COUPLE design of the M-10
suspension displaces the rear arm as the front arm is
compressed. This means that when you raise the front
limiter strap, at some point you will collapse the rear
suspension arm, which will affect SAG height and reduce
rear suspension travel.
Initial M-10 Suspension Set-up Chart
NOTE: The initial M-10 suspension set-up chart was not available at
the time of printing. Please see your Polaris dealer.
53
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THE PERFECT FIT
Handlebar Adjustments
Handlebar Position
Use the RIDER SELECT feature to adjust handlebar position. See
page 27.
Handlebar Angle
Follow these steps to adjust
handlebar angle at the handlebar
block.
1
1. Remove the handlebar cover (1)
2
to expose the handlebar and the
four adjuster block bolts (2).
2. Using a 7/16″ wrench, loosen the
four nuts (3) on the bottom of the
adjuster block (turn handlebar to
left or right for access to back
nuts).
NOTE: If necessary, pry the
blocks apart with a
screwdriver.
3
3. Adjust the handlebar to the desired height. Be sure handlebars,
brake lever and throttle lever operate smoothly and do not hit the
gas tank, windshield or any other part of the machine when turned
fully to the left or right.
4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-18
Nm).
NOTE: Torque the front bolts first.
5. Reinstall the handlebar cover.
54
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THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.
NOTE: The accessory tether switch is available for all models.
Order PN 2870668.
Use only Polaris parts and accessories on your Polaris snowmobile.
Use of unapproved parts and accessories may result in:
S Non-compliance with government/industry requirements
S Voiding of warranty
S Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems.
NOTE: Exhaust systems are critical safety areas that must use
approved Polaris parts. Please see your Polaris dealer for
service.
55
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THE PERFECT FIT
Traction Products
Studs
Before equipping your machine with traction products, be aware of the
laws in your area pertaining to the use of traction products.
Use only Polaris traction products on your snowmobile. Track
warranties are void if track damage or failure results from improper or
excessive stud installation or the use of non-Polaris traction products.
See your dealer about installing studs and/or carbides.
CAUTION
Always install wear strips before installing studs. Failure to install
wear strips may result in cooler or tunnel damage. See page 57.
Never add shims to the wear strip. Track damage will result
because of lack of clearance between upper carrier wheels and
track.
Use of studs longer than the recommended length on machines
equipped with center coolers will result in center cooler damage
or damage to the tunnel.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering
ability may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are
available. See your dealer.
CAUTION
Aggressive studding patterns may require grinding protruding
stud bolts flush to prevent idler wheel damage. Maintain track
tension on studded tracks on the tight side of the spec to prevent
heat exchanger damage. Center of stud must be at least 1 1/8″
(2.86 cm) from outside edge of the track.
56
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THE PERFECT FIT
Traction Products
n 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
111.
If your machine 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.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. Install Wear Strip Kit P/N 2874687.
Wear strips are designed for a specific stud length. See your dealer’s
studding chart for recommended traction accessories.
CAUTION
Whenever wear strips are relocated, be sure there’s adequate
stud clearance to the heat exchangers. Lack of clearance may
result in damage to heat exchangers.
57
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PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the
referenced pages. Look for a checkmark (n) on the referenced pages
to locate the pre-ride inspection items.
See Page
101, 103
62
Item
Drive Belt Condition
Steering System
Recoil Rope
62
Coolant Level
91
Park Brake Lock/Brake Lever/Brake System
Auxiliary Shut-Off Switch (Engine Stop Switch)
Ignition Switch
60, 61, 94
63
63
Taillight/Brakelight/Headlight
Suspension Mounting Bolts
Skags (Wear Bars)
63
113
57, 111
113
Ski Saddle and Spindle Bolts
Hood Straps/Latches
62
Seat Latches (if equipped)
Throttle Lever/Safety Switch
Rear Wheel Idler Bolts
N/A
59, 71, 72
108, 113
63
Tether Switch/Strap
Track Alignment/Condition
Slider Condition
62, 106
112
Chaincase Oil Level
84
Injection Oil Level
67
58
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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.
n 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
function smoothly, or if you discover excessive lever freeplay, DO
NOT start the engine. Have the throttle serviced immediately.
n Throttle Safety Switch
Test the throttle safety switch system before the machine is operated.
See page 71 for procedure.
59
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Brakes
Always check the
1/2″
(1.3 cm)
following items for proper
operation before starting
the engine.
Brake Lever Travel
Squeeze the brake lever.
It should move no closer
to the handgrip than 1/2″ (1.3 cm).
A smaller distance indicates low brake fluid level or air in the
hydraulic system. Refer to the brake bleeding information on page 97.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 96.
Check for the presence of air in the fluid system. See page 97 for more
information, or see your dealer for service.
WARNING
Continued use of “spongy” brakes may cause a complete loss of
brakes, which could result in serious injury or death. Always have
the brakes serviced at the first sign of sponginess.
60
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Park Brake Lever Lock
Use the park brake lever lock only when you want the machine to
remain stationary; for example, when parked on an incline for a period
of five minutes or less.
2
3
4
1. Brake Lever
2. Park Brake Lever Lock
3. Master Cylinder Reservoir /
Cover
1
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.
NOTE: 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 in the analog gauge will light up if the park brake lever
lock is set while the engine is running. It will also be lit when the
service brake is in use. If the park brake light does not come on when
the park brake or service brake is in use, have it serviced by your
dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will
return to the unlock position.
WARNING
If the park 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.
61
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Steering System
Manually turn the skis completely to the right and to the left. If any
difficulty is encountered, remove any ice and snow build-up that may
be obstructing the steering linkage.
n 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
lubrication would include frozen bodies of water without snow cover,
icy trails, and no-snow conditions.
NOTE: Track damage or failure caused by operation on ice or poor
lubrication conditions voids the track warranty.
n Hood Latches
The hood of the snowmobile protects the operator from moving parts
as well as aiding in sound emission control and other functions. Under
no circumstances should your snowmobile be operated with the hood
open or removed. Always ensure that the hood straps are in good
condition and that the latches are securely in place before operating the
snowmobile.
n 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.
62
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PRE-RIDE INSPECTIONS
Start the Engine and Check
n Engine Stop Switch: Check the auxiliary shut-off switch for
proper operation. Push the switch down to stop the engine. Pull it
up to allow restarting.
n Ignition Switch: Make sure the engine stops when the ignition
switch is turned to OFF.
n Tether Switch: If your machine has a tether switch, remove the
tether from the switch to make sure the engine stops immediately.
n Lighting: Check the headlight (high and low beam), taillight, and
brake light. Replace burned out lamps before operating.
n Mirror Adjustment (if equipped): Adjust the mirrors so they can
be used to their full advantage.
n Operating Area: Before driving away, check your surroundings.
Be aware of obstacles and make sure bystanders are a safe distance
from the machine.
63
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OPERATION
Starting the Engine
WARNING
Before starting the engine, always refer to all safety warnings
pertaining to snowmobile operation. Never start your snowmobile
without checking all components to be sure of proper operation.
See Check Before Starting the Engine beginning on page 59.
Do not depress the throttle until the engine starts.
1. Turn the key to the ON position.
2. Pull the engine stop switch up to the RUN position.
3. 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.
4. If not equipped with electric start, grasp starter handle and pull
slowly until the recoil engages; then pull abruptly to crank the
engine.
NOTE: It may require as many as eight to ten pulls to prime the fuel
system and start the engine if the fuel tank has been
completely emptied.
5. Repeat the cranking procedure as needed until the engine starts.
CAUTION
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.
To avoid injury and/or engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.
64
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OPERATION
Slide Rail and Track Cooling
CAUTION
Inadequate cooling and lubrication will lead to overheating of the
slide rail and track, resulting in premature wear and failure.
Reduce speeds and frequently drive into fresh snow to allow
adequate cooling and polishing of the slide rail and track
surfaces. Avoid operating on ice, hard-packed surfaces or roads.
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of gasoline with one pint of Polaris injection oil for each five
gallons of fuel. This, in addition to the lubrication supplied by the
injection system, will assure proper engine break-in.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use. Vary the throttle openings and machine speeds to
reduce friction on all close-fitting machined parts, allowing them
to break in slowly without damage.
Use of any lubricants other than those recommended by Polaris
may cause serious engine damage. We recommend the use of
Polaris lubricants for your vehicle.
Drive with extra caution during the break-in period. Perform
regular checks on fluid levels, lines, and all other important areas
of the machine.
65
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OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. Maintain the oil
level at the bottom of the filler neck. See page 67.
CAUTION
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.
Variable Exhaust System
All snowmobile engines equipped with variable exhaust valves should
use VES II 2 Cycle Oil (see chart below).
Oil Recommendations
Engine lubrication comes from oil added to the fuel and oil injection
systems. We highly recommend the use of only Polaris products.
Polaris lubricants provide the best protection for your Polaris engine.
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.
Engine
Style
Premium
2-Cycle
Premium Gold
2-Cycle
VES II
2-Cycle
Liquid Cooled
w/VES
Good
Better
Best
66
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OPERATION
Oil
n Low Oil Level
The low oil indicator light will alert the operator if the oil level is low.
Add oil before further operation of the snowmobile. See page 66 for oil
recommendations.
CAUTION
Operating the snowmobile without adequate engine lubrication
can result in serious engine damage. Always add oil when the
low oil indicator light comes on.
Always check and fill the oil tank
when refueling. Maintain the oil
level at the bottom of the filler neck.
Maintaining adequate oil in the oil
tank will prevent system aeration
and possible loss of pumping action,
which could result in engine
damage.
NOTE: The engine may be
operated as long as oil is
visible in the oil bottle. If
oil is not visible, continued
operation may cause
serious engine damage.
NOTE: The Polaris oil cap on the oil bottle is vented to allow proper
oil flow. See your Polaris dealer for recommended
replacement parts.
67
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OPERATION
Fuel
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel outdoors or in a well-ventilated area.
S Always turn off the engine before refueling.
S Do not overfill the tank. Do not fill the tank neck.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area. Engine
exhaust fumes are poisonous and can cause loss of conscious-
ness or death in a short time.
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.
68
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OPERATION
Fuel
For peak performance, Polaris recommends the use of 91 octane or
higher fuel. Although 87 octane fuel is usable, some engine
performance will be lost and fuel economy will decrease. Do not use
fuel lower than 87 octane.
CAUTION
Operating with obstructed fuel systems will result in serious
engine damage. Perform maintenance as recommended.
Damage to the fuel pump will occur if the snowmobile is operated
with an empty fuel tank. Do not allow the snowmobile to run out
of fuel. Always refuel when the level is low.
Prolonged exposure to petroleum based products may damage
paint. Always protect painted surfaces when handling fuel.
Fuel Level
The fuel symbol and the last fuel bar on the MFD gauge will blink
when the fuel level reaches 1/8th tank. There will be approximately
one gallon of fuel remaining. Refuel as soon as possible. Do not allow
the snowmobile to run out of fuel.
Fuel System Deicers
If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 milliliters per liter) of gasoline to prevent engine damage
resulting from fuel system icing and lean fuel mixtures. Never use
deicers or additives containing methanol. Polaris also recommends the
use of Carbon Clean Plus. See page 117 for the part numbers of Polaris
products.
If you use oxygenated fuel containing ethanol, additional alcohol
deicers or water absorbing additives should not be used.
69
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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
snowmobile 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.
NOTE: It will take longer to warm up the
track sufficiently during colder outdoor temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the machine to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
70
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OPERATION
n Engine Stop Switch
Push down on the engine stop
switch (A) to ground out the
ignition and stop the engine
quickly. Pull the switch up to the
ON position to allow restarting.
A
n Throttle Safety Switch
The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.
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 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.
B
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 exerting pressure
on the pivot pin in the direction
shown in the illustration (B).
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
71
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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 throttle body 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 possible.
72
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OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 71 for more information about the
engine stop switch and throttle safety switch.
SYSTEM
WHAT IT DOES
THROTTLE
CONDITION
Ignition Switch
Interrupts ignition circuit
Slows jackshaft
All
All
All
All
All
Brake
Engine Stop Switch
Throttle Safety Switch
Tether Switch (Option)
Interrupts ignition circuit
Interrupts ignition circuit
Interrupts ignition circuit
Emergency Starting
If the recoil starter system fails, an emergency start strap is provided in
the tool kit.
1. Open the hood.
2. Remove the left side panel.
3. Remove the air box (pull
aggressively).
4. Using the belt removal
tool, follow the directions
on the air box to relieve
belt tension.
5. Starting at one of the tower
struts, wind the strap counterclockwise around the clutch as shown.
WARNING
Serious injury can result from wrapping the start strap around
your hand while using the emergency starting procedure. DO
NOT wrap the start strap around your hand. Keep all bystanders
and loose clothing away from the snowmobile when using the
emergency starting procedure.
6. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine. Repeat until the engine starts.
7. Reinstall the air box and side panel.
8. Close and secure the hood.
73
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OPERATION
Electronic Reverse (PERCt)
Electronic reverse will activate only if the engine RPM is below 4000.
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.
S Shift to or from reverse only when the snowmobile is stopped
and when engine speed is at idle.
S Look behind the vehicle before and while backing.
S Avoid sharp turns.
S Apply throttle slowly.
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
second, 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.
NOTE: The maximum engine RPM will be 6000 when in reverse.
NOTE: 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.
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OPERATION
Daily Storage
At the end of each ride, park the
snowmobile on a level surface and
support it at the rear with an
appropriate track stand. The track
should be suspended approximately 4″
(10 cm) off the ground.
Remove the key and cover the
machine.
Towing
WARNING
Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting
in serious injury or death. DO NOT tow toboggans, sleds,
saucers, or any type of vehicle with a rope. Only a stiff metal
pole connecting the towed object and the tow hitch on the
snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2
meters) long to prevent any possibility of contact between the
snowmobile’s track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to
maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it
isn’t possible to use a rigid tow bar, attach the tow rope to the ski
spindles (not to the ski loops) to prevent damage to the steering
components. Remove the drive belt before towing, and have someone
ride on the towed snowmobile to operate the brake and steering when
necessary.
CAUTION
Towing a disabled snowmobile with the drive belt in place can
result in serious damage to the engine and drive system. Always
remove the drive belt from a disabled snowmobile before towing.
75
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MAINTENANCE
Emission Control Information
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission
control information (ECI) label and a factory--installed emissions
information hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory--installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. The emission control system designation
per SAE J1930 is EM. If your snowmobile is equipped with a check
engine light and it comes on, you must take your snowmobile to a
qualified dealer for diagnostic service. Specifications and adjustments
for engine tune--ups are located in the Service Manual, which is
available to your qualified service technician. Reverse (if equipped)
must not be engaged during engine tune--ups.
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MAINTENANCE
Emission Control Information
Owner’s Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty on
page 130, and read the maintenance section of your owner’s manual.
You are responsible for ensuring that the specified maintenance is
performed, including the emission--related maintenance outlined in
these sections of the manual.
You must inspect the air intake system on your snowmobile prior to
each use (including the airbox foam filter and hood foam filters) and
clean these components as necessary. Polaris considers the specified
maintenance for the spark plugs, oil changes, air intake system and
exhaust valves to be critical emission--related maintenance. The
specified maintenance for the fuel filter is recommended additional
emission--related maintenance. Any qualified repair shop or qualified
person may maintain, replace, or repair the emission control devices or
systems on your snowmobile. Polaris recommends that you contact an
authorized Polaris dealer to perform any service that may be necessary.
77
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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
outlined in this manual. Record maintenance and service in the
Maintenance Log beginning on page 132.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1000 miles (1600 km). These inspections should be
performed by a qualified service technician. For continued optimum
performance and component life, continue maintenance checks at 1000
mile (1600 km) intervals.
All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the
registered owner. If, during the course of the warranty period, part
failures occur as a result of owner neglect in performing recommended
regular maintenance, the cost of repairs are the responsibility of the
owner.
Personal safety is critical when attempting to service or make
adjustments 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 comfortable performing these tasks yourself, contact an authorized
Polaris dealer for service.
CAUTION
Hot components can cause damage to plastic. Always make
sure the exhaust system and engine have cooled before tipping
the snowmobile on its side for service or inspection.
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MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.
See
Frequency
Page
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
CLUTCH
Clutch Offset Alignment
(without belt)
100
I
I
I
Drive Belt Condition
Clutches (disassemble)
Belt Tension
101
100
--
I
C
I
I
C
I
I
C
I
I
I
I
Clutch Sheaves
100
I
I
I
ENGINE
Engine Mounts
--
--
I
I
I
I
I
I
I
I
I
Recoil Rope
Engine Torque Stop
Cylinder Head Bolts
Cylinder Base Nuts
Ignition Timing BTDC
VES System
103
--
I
I
I
I
I
I
--
I
I
I
I
--
I
I
I
--
C
I
C
I
C
R
I
I
I
I
I
Coolant Level
91
--
Coolant Hose
I
I
Heat Exchangers
Coolant Circulation
Coolant Leaks
92
--
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
Spark Plug Condition
Exhaust Pipe
87
90
90
I
I
R
I
Exhaust Retaining
Springs
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
79
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MAINTENANCE
Periodic Maintenance Interval Table
See
Frequency
Page
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
BRAKES
Hose Routing
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Hose Condition
Fluid Leaks
--
Brake Pads
Brake Disc
94
--
Parking Brakes
Brake System
Brake fluid
61
59, 94
96
R
FUEL MANAGEMENT
I
Idle RPM
--
I
I
I
I
Throttle Lever
59, 72
--
I
I
I
Oil Pump Lever
(synchronize)
I
I
I
Throttle Cable
Vent Lines
83
--
L
I
L
I
L
I
I
I
Throttle Position Sensor
Fuel Lines
--
I
I
I
88
89
89
--
I
I
I
I
Oil Filter
R
I
R
I
Oil Lines
I
I
Air Box
I
I
I
I
ELECTRICAL
Auxiliary Shut-Off Switch
Throttle Safety Switch
Ignition Switch
Taillight
63
59, 71
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
63
Brakelight
63
Headlight
63
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MAINTENANCE
Periodic Maintenance Interval Table
Frequency
See
Page
Item
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
CHASSIS
Ski Toe Alignment
--
--
I
I
I
I
I
I
I
I
I
I
I
I
Suspension
Mounting Bolts
I
I
I
I
C
I
Steering Fasteners
--
--
Rear Suspension
Fasteners
Suspension Shock Oil
Cooling Fins and Shroud
Drive Shaft Bearings
Jackshaft Bearings
Skags (Wear Bars)
Ski Saddle/Spindle Bolts
Drive Chain Tension
Hood Straps
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
83
115
56
--
L
L
I
L
L
I
L
L
I
I
I
I
I
I
I
I
I
I
93
62
108
108
82
I
I
I
I
I
I
Rear Wheel Idler Bolts
Idler Bolt Jam Nut
I
I
I
I
I
I
Rear Suspension Pivot
Shafts
L
I
L
I
L
Camber Alignment
Handlebar Centering
Tether Switch and Strap
Track Alignment
Track Tension
--
--
I
I
I
I
I
I
I
I
63
106
107
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Front Limiter Strap
Slider Condition
112
84
Chaincase Oil
I
I
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
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MAINTENANCE
Lubrication
Front Suspension
The Fusion front suspension and steering components do not
require lubrication.
Rear Suspension
Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at 500 miles (800 km) initially, every 1000 miles (1600 km)
after that, and before off-season storage each year. Lack of lubrication
will adversely affect your ride and the life of the suspension. For more
information about suspension lubrication and adjustments, see your
Polaris dealer.
IQ Rear Suspension
L
L
L
M-10 Rear Suspension
L
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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.
+
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MAINTENANCE
Lubrication
n Chaincase Oil
Check the chaincase oil level at the
intervals outlined in the
maintenance charts beginning on
page 79. 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.
3
Polaris recommends the use of
Polaris Synthetic Chaincase Lube.
See page 117 for the part numbers of
Polaris products.
1
2
Oil Check
1. Position the machine on a level surface.
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
4
completely
3. Install a new sealing washer on
the drain plug.
NOTE: The sealing surfaces on the drain plug and the oil tank
should be clean and free of burrs, nicks or scratches.
4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
5. Remove the fill plug.
6. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.
7. Reinstall the fill plug, making sure it is seated properly.
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MAINTENANCE
Spark Plugs
A new engine can cause temporary spark plug fouling due to the
preservative added during the assembly process. Avoid prolonged idle
speeds, which cause plug fouling and carbonization.
Change the spark plugs every 2000-2500 miles (3200-4000 km).
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. A spark plug with a heat range too high will always
cause engine damage if the engine is operated in conditions more
severe than intended for that plug. Always use the spark plugs
recommended for your snowmobile.
S Use recommended spark plugs with the proper gap. See your Own-
er’s Manual Supplement for the recommended spark plug and gap.
S Use only resistor-type spark plugs.
S Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
S Always carry spare spark plugs.
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MAINTENANCE
Spark Plugs
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. Normal
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect throttle body adjustments.
2. Wet Fouled
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil or
use of non-recommended injection oil.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2
2. Using the special wrench provided in the
tool pouch, rotate the spark plug
counterclockwise to remove.
3. Reverse the procedure for spark plug
installation.
4. Torque to 18-22 ft. lbs. (24-30 Nm).
5. Reinstall the spark plug cap.
87
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MAINTENANCE
Intake Filter
The intake foam
filter (1) limits snow
ingestion into the
intake system. When
operating in loose
powder snow, check
the foam filter
periodically to remove
any accumulation of
snow.
1
Fuel Injectors
All fuel injector service must be performed by an authorized Polaris
dealer. Do not attempt to clean or service the fuel injectors.
Fuel Pump
All fuel pump service must be performed by an authorized Polaris
dealer. Do not attempt to service the fuel pump.
Fuel Lines
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal
deterioration from weather and fuel compounds may occur. Replace
worn or damaged fuel lines promptly.
CAUTION
Kinking the fuel lines or using a pliers or similar tools to remove
fuel lines may cause damage to the lines. If a fuel line has been
damaged or kinked, replace it promptly.
88
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MAINTENANCE
Oil Filter
Inspect oil line condition at
1000 miles (1600 km). The oil
filter should be changed
annually or every 1000 miles
(1600 km). The oil filter is
located on the left side of the
bulkhead behind the drive
clutch.
Have your dealer perform the
filter change and bleeding
operation.
NOTE: The direction of the
arrows indicates the
direction of flow through
the filter.
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MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). To inspect, allow the engine and exhaust system to
cool completely. Open the hood and inspect the muffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.
WARNING
Hot exhaust system parts can cause serious burns. Allow
adequate time for the exhaust system to cool. Never perform this
procedure with the engine running.
Cooling System
Coolant
The coolant supplied in the system is a 60/40 mixture of
ethylene-glycol and distilled water. This mixture provides protection
against freezing. Contact your dealer if greater protection is required.
Use Premium 60/40 anti-freeze coolant, which is already premixed and
ready to use. Do not dilute with water. Never exceed a 60%
antifreeze/40% water mixture. See page 117 for the part numbers of
Polaris products.
NOTE: Never add tap water to the cooling system. Minerals cause
deposits and may react adversely with the metals in the
engine and cooling system.
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MAINTENANCE
Cooling System
Coolant High Temperature Indicator Light
The high temperature indicator light is controlled by a switch in the
ECU. If the engine coolant reaches a certain temperature, the switch
completes a circuit that turns the light on. If you must drive your
machine after the high temperature indicator light has come on, drive
slowly and stop frequently to allow the engine to cool down. See your
dealer.
n Coolant Level
The engine coolant level is controlled by the recovery system. The
recovery system components are:
S Coolant bottle or overflow tank
S Engine filler neck
S Pressure cap
S Connecting hoses
Always maintain the coolant level at the “FULL COLD” mark on the
coolant bottle (when engine is cold) to prevent overheating and serious
engine damage.
CAUTION
Operating the snowmobile with insufficient coolant will result in
overheating and serious engine damage. Always maintain the
coolant level as recommended.
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine,
the system should be completely drained every two years and a fresh
mixture of antifreeze and distilled water should be added. This service
must be done when the engine is cold. Ask your Polaris dealer to
check the coolant when he performs the fall tune-up on your
snowmobile.
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MAINTENANCE
Cooling System
Bleeding the Cooling System
Use of a non-standard pressure cap will not allow the recovery system
to function properly. If the pressure cap needs replacement, contact
your dealer for the correct part.
WARNING
Steam and hot liquids will cause serious burns to your skin.
Never bleed the cooling system or remove the pressure cap when
the engine is warm or hot.
CAUTION
If coolant flow becomes restricted or plugged, coolant loss, air
lock or engine damage may result. Most cooling systems are
equipped with a filter that should be periodically inspected or
replaced.
1. Remove the pressure cap and fill the coolant bottle with the
recommended coolant to the “FULL COLD” mark.
2. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.
3. Add coolant to the coolant bottle to the “FULL COLD” mark.
4. Start the engine and run at a fast idle for two to three minutes.
Loosen the bleed screw occasionally to purge any trapped air.
5. Stop the engine and check the coolant bottle level. Fill as required.
6. Feel the heat exchangers under the running boards. If the system is
bled properly, they’ll be warm to the touch. If they’re not, repeat
step 4.
7. Replace the pressure cap.
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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
counterclockwise to move all
chain slack to the tensioner side.
Lock the brake lever lock, or
have an assistant hold the brake
lever firmly.
2
2. Loosen the adjuster bolt jam
nut (1).
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
n Hydraulic Brake Inspection
Inspect the brake lever
reserve before each use of
the snowmobile.
A
Firmly depress the brake
lever and measure the
clearance between the lever
and handlebar grip. This
distance, called brake lever
reserve (A), should be no less than 1/2″ (1.3 cm).
Brake pads must be replaced when the brake pad material becomes
thinner than the backing plate (approximately 1/16″). 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″).
94
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MAINTENANCE
Brakes
Brake Components
1. Brake Caliper
2. Brake Disc
1
3. Backing Plate
4. Brake Pad Material
(Replace when thick-
ness is less than
1/16″/1.5mm).
Excessive Lever Travel
3
Hydraulic brakes are self-adjusting,
but if excessive brake pad clearance
develops (see page 94), bring the
machine to an authorized Polaris dealer
for inspection and adjustment.
95
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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.
WARNING
Keep the master cylinder cover free of dirt and debris. The vent
slits allow for diaphragm movement, and if they become plugged,
movement of brake fluid below the diaphragm may be restricted,
altering brake function.
CAUTION
Brake fluid will damage decals, paint and some plastics. Always
wipe up spills immediately.
Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 117 for the part numbers of Polaris
products.
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.
96
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MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING
Operating the vehicle with a spongy brake lever can result in loss
of brakes, which could cause an accident and lead to serious
injury or death. Never operate the vehicle with a spongy-feeling
brake lever.
During the bleeding procedure, keep the brake handle as level as
possible. The reservoir must be in this position to minimize the
possibility of air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16″ (.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 96.
8. Reinstall the gasket and cover.
97
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MAINTENANCE
Lights
NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin
leaves a residue, causing a hot spot that will shorten the life
of the lamp. If fingers do touch the bulb, clean it with an
alcohol-moistened towel.
Removing Halogen Bulbs
1. Remove the plenum covering from
the headlight assembly.
2
2. Lift the rubber boot to expose the
bulb.
3
3. Push down on the spring (1) to
release it from the housing.
4. With the wire harness (2)
attached to the bulb (3),
withdraw the bulb from the
housing.
1
5. Grasp the bulb by its metal base and carefully separate the bulb
from the harness.
Installing Halogen Bulbs
1. Hold the bulb by its metal base and install it into the wire harness.
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.
98
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MAINTENANCE
Lights
Taillight/Brakelight Replacement
1. Open the rear storage
compartment.
2. Reach into the compartment
and locate the socket
assembly above the door
opening.
3. Turn the socket
counterclockwise 1/4 turn.
4. Carefully pull the socket
assembly away from the
taillight.
5. Replace the bulb and reinstall
the socket assembly.
99
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MAINTENANCE
Clutch System
WARNING
If you become aware of higher than normal clutch engagement or
an unusual vibration or shift pattern, see your dealer immediately.
Do not operate the machine until repairs have been made.
All clutch maintenance and repairs must be performed by an
authorized Polaris dealer. Any unauthorized modifications to
clutches, such as adding or removing weights, will void the
warranty.
CAUTION
The bushings in the weights and rollers of Polaris clutches are
made of a material that may be damaged if lubricated. Do not
lubricate clutch bushings.
Periodically inspect clutch sheaves for damage, wear or belt residue.
To maintain optimum performance, clean with non-oil based cleaners
such as isopropyl alcohol.
Clutch Alignment and Offset
Clutch alignment offset (A) is important for
maintaining optimum performance. See your
Owner’s Manual Supplement for the
recommended offset between the drive and
driven clutches with the belt removed.
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. See your
dealer for service and adjustments.
A
NOTE: A worn belt will continue to function, but
will not deliver maximum performance.
Always carry a spare belt in case of an
emergency.
100
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MAINTENANCE
Clutch System
n Drive Belt Condition
Periodically check the condition and tension of the drive belt, and
always carry a spare. 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.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting
the snowmobile.
Drive Belt Removal
1. Be sure the key switch is off and the engine has come to a
complete stop. Apply the brake (or lock the parking brake if
equipped).
2. Open the hood. Remove
the left side panel to
access the drive clutch.
A
3. Locate the L-wrench in
the tool kit. Install the
wrench into the open
threaded hole in the outer
sheave of the clutch (A).
4. Turn the wrench
clockwise until the
sheaves open far enough
to remove the belt.
101
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MAINTENANCE
Clutch System
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back the
slack.
NOTE: To ensure satisfactory belt
life, install belts so they
operate in the same
direction of rotation by
positioning the
identification numbers so
that you can read them. If
required, separate the
sheaves as outlined in the
belt removal procedures.
2. Rotate the L-wrench counter-clockwise to tighten the sheaves
while working the belt to the outer edge of the sheaves.
3. Remove the wrench and store it in the tool kit.
4. Reinstall the side panel.
5. Close and secure the hood.
102
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MAINTENANCE
Clutch System
n Drive Belt Deflection
Measure belt deflection with both
clutches at rest and in their full
neutral position.
A
B
Place a straight edge on the belt (A)
and apply downward pressure while
measuring at point B. This
measurement should be 1 1/4” (3.2 cm).
Drive Belt Adjustment
TEAM Clutch
1. Loosen the 7/16” jam nut on the belt width adjuster.
2. Using a 1/8” Allen wrench, adjust the threaded set screw as
needed.
NOTE: Turn the set screw in (clockwise) to increase the distance
between the sheaves and out (counterclockwise) to decrease
the distance.
3. Tighten the jam nut.
Torque Stop
Periodically check torque stop (1) clearance. With clutches in proper
alignment, the clearance should be .010″-.030″ (.25-.75mm) from the
engine case. Adjust if necessary. Lock the jam nut.
1
.010″-.030″
(.25-.75mm)
103
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MAINTENANCE
Tool Kit
A tool kit is included with each machine for emergency and routine
maintenance. Always keep the tool kit with the snowmobile.
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.
Maintenance Items
The tools and maintenance items mentioned in this book, as well as a
long line of other Polaris accessories, are available at your Polaris
dealer.
104
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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 snowmobile 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 (A).
Bend the track to check
for breakage.
4. Replace the track if any
rod damage is found.
A
Track Lubrication
WARNING
Operating with insufficient lubrication between the slider and track
guide clips can cause track failure, loss of vehicle control and loss
of braking ability, which can result in serious injury or death. Avoid
operating for extended periods on ice and other surfaces that
have little or no snow for lubrication.
The slide rail needs snow for lubrication. Excessive wear indicates
insufficient lubrication. A new slider can cause faster heat build-up in
limited lubrication, resulting in excessive wear.
NOTE: If excessive slider wear occurs due to poor snow conditions,
additional wheel kits are available. See your dealer for more
information.
NOTE: Track damage or failure caused by operation on ice or under
other poor lubrication conditions will void the track warranty.
105
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MAINTENANCE
Track Maintenance
n Track Alignment
Periodically check that the track is centered and running evenly on the
slide rails. Misalignment will cause excessive wear to the track and
slide rail.
1. Safely support the rear of the machine with the track off the
ground.
2. Start the engine and apply a small amount of throttle until the
track turns slowly at least five complete revolutions. Stop the
engine and let the track come to a stop (do not apply brakes).
3. Inspect track alignment
by looking through the
track window to make
sure the rails (A) are
evenly spaced on each
side. If the track runs to
the left, loosen left
locknut and tighten the
left adjusting bolt. If the
track runs to the right,
loosen right locknut and
tighten the right
adjusting bolt.
4. After adjustments are
A
complete, tighten locknuts
and torque idler shaft bolts
to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
106
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MAINTENANCE
Track Maintenance
WARNING
Moving parts can cut and crush body parts. When performing the
checks and adjustments recommended on the following pages,
stay clear of all moving parts. Never perform track measurement
or adjustments with the engine running.
Track Tension
Track adjustment is critical for proper handling. Always maintain
correct tension and alignment.
Track Tension Data Chart
Suspension
Weight
Measurement
Location
Slack
Measurement
IQ
10 lbs. (4.54 kg)
10 lbs. (4.54 kg)
16″ ahead of rear
3/8″ - 1/2″
(1 - 1.3 cm)
idler shaft
M-10
16″ ahead of rear
7/8″ - 1 1/8″
idler shaft
(2.2 - 2.9 cm)
NOTE: 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.
NOTE: Measure at the point where the weight is hanging.
107
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MAINTENANCE
Track Maintenance
Track Tension
4. Check for specified slack (1) between the wear surface of the track
clip and the plastic slider. Refer to the Track Tension Data Chart on
page 107.
If the track needs adjustment:
5. Loosen the rear idler shaft bolt (2).
6. Loosen the locknuts (3).
2
4
3
1
10 lbs.
(4.5 kg)
16″
(40 cm)
7. Tighten or loosen the track adjusting screws (4) to provide equal
adjustment on both sides of the track.
8. Repeat the measurement on the other side of the track.
NOTE: Check more frequently when the machine is new.
9. Start the machine and slowly rotate the track at least five
revolutions. Let the track come to a stop (do not apply brakes).
10. Check track alignment (see page 106) and adjust as necessary.
11. Tighten the locknuts.
12. Tighten the idler shaft bolts.
13. Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
108
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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.
+
+
109
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MAINTENANCE
Steering System
Ski Alignment
WARNING
Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Do not attempt to
change the ski alignment or camber adjustment. See your
Polaris dealer.
With the handlebars in a straight ahead position, and with vehicle
weight compressing the suspension, measure from the straight edge of
the skis at the center of the ski mounting bolt. The measurement
between the skis at point X should be 1/8″ to 1/4″ greater than the
measurement at point Y.
NOTE: If the skis are misaligned, we recommend that your dealer
correct the alignment, since camber adjustment may also be
affected.
X
10″
10″
Y
110
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MAINTENANCE
Steering System
n Ski Skags
WARNING
Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death.
See your dealer’s studding chart for recommended skags. If you
install longer or more aggressive carbide skags than the original
equipment, it may also be necessary to add track studs to
maintain proper vehicle control while turning on hard-packed
snow or ice.
Check skags before each use of the snowmobile to ensure positive
steering characteristics. Skags must be replaced when worn to half their
original diameter.
NOTE: Carbide skags must be replaced if any abnormal wear or
chipping is found.
Skag Replacement
1. Raise and support the front of
the machine so the skis are
approximately 6″ (15.2 cm)
from the ground.
2. Remove the attaching nuts
and pry the skag (1)
downward.
3. Remove the front end of the skag.
4. Remove the rear end of the skag.
5. Reverse the steps to install a skag.
111
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MAINTENANCE
Suspension Maintenance
n Slider Wear
Measure slider thickness at
several points along the
rail. Have your dealer
replace the slider when it’s
worn to the top of the wear
groove (A). Do not operate
the snowmobile if slider
thickness measures less than
7/16″ (1.1 cm) at any
point.
7/16″
(1.1 cm)
A
112
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MAINTENANCE
Suspension Maintenance
n Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your snowmobile’s reliability and
cause needless repairs and down time. Before beginning any
snowmobile trip, a visual inspection will uncover potential problems.
Check the following items on a weekly basis or before any long trip:
n Check suspension mounting bolts for tightness.
n Check rear idler wheel bolts for tightness. See page 108.
n Check rear idler adjusting bolt locknuts for tightness.
n Check front torque arm limiter strap condition.
n Check slide rail condition.
n Check track tension. See page 107.
n Lubricate all rear suspension components. See page 82.
n Check ski runner/skag condition.
n Check ski spindle bolts for tightness.
n Check tie rod end nuts for tightness.
113
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MAINTENANCE
Extended Storage
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components. See page 117 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
surfaces before beginning preservation with waxes and rust inhibitors
(grease, oil or paint).
The machine should be stored in a dry garage or shed, out of direct
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
Controls and Linkage
All bushings, spindle shafts, tie rod ends, and cables should receive a
light coat of oil or grease.
114
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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 Protection
Proper preparation of the engine and fuel system is vital to the
prevention of rust and corrosion on precision engine parts during
storage. Whenever the machine is stored for a period of more than 60
days, the engine must be fogged with fogging oil. Follow the engine
fogging instructions provided on the 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. See page 69.
115
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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.
See illustration.
Transporting the Snowmobile
Whenever the snowmobile is transported:
1. Be sure the fuel cap and oil cap are
installed correctly.
2. Always tie the snowmobile to the
transporting unit securely using
suitable straps.
3. Remove the ignition key to prevent loss.
116
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POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
2870791
2871098
2871097
2871240
2871721
2871722
2872347
2874438
2874439
2874443
Fogging Oil (12 oz. Aerosol)
Premium 2-Cycle Engine Oil (qt.)
Premium 2-Cycle Engine Oil (gal.)
Premium 2-Cycle Engine Oil (2.5 gal.)
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)
VES II Synthetic 2-Cycle Engine Oil (qt.)
VES II Synthetic 2-Cycle Engine Oil (gal.)
VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)
Chaincase Lubricants
2873105
2872951
Synthetic Chaincase Lubricant (qt.)
Synthetic Chaincase Lubricant (12 oz.)
Grease / Specialized Lubricants
2871312
2871322
2871423
2871329
Grease Gun Kit, Premium All Season (3 oz.)
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Dielectric Grease (Nyogelt)
Coolant
2871323
2871534
Anitfreeze, 60/40 Premix (gal.)
Anitfreeze, 60/40 Premix (qt.)
Additives / Miscellaneous
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT 4 Brake Fluid (12 oz.)
Engine Degreaser (12 oz.)
Isopropyl
2871326
2870652
2872189
2872893
2870505
2872889
2872890
Brake and Clutch Cleaner
Carb and Throttle Body Cleaner
117
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TROUBLESHOOTING
Engine Troubleshooting
CAUTION: Unless you have experience and training in two-cycle
engine repair, see your dealer if technical problems arise.
Problem
Probable Cause Solution
Erratic engine
operating
Drive clutch binding
S
SEE YOUR DEALER.
RPM during
acceleration
or load varia-
tions
Driven clutch
malfunction
S
SEE YOUR DEALER.
Harsh drive
clutch
Drive belt worn or
too narrow
S
S
S
S
S
S
S
Replace the drive belt.
SEE YOUR DEALER.
Replace the drive belt.
SEE YOUR DEALER
engagement
Excessive belt/sheave
clearance
Drive belt
turns over
Wrong belt for
application
Clutch alignment out
of spec
Engine mount broken
or loose
Inspect and replace. SEE YOUR
DEALER.
Machine fails
to move
Clutch jammed
Check for twisted belt or broken spring.
SEE YOUR DEALER.
Track jammed
Foreign object may be caught or the slider
melted to the track clips due to lack of lu-
brication.
S
S
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.
118
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Noise in drive
system
Broken drive clutch
components
S
SEE YOUR DEALER.
Bearing failure/
chaincase, jackshaft,
or front drive shaft
S
SEE YOUR DEALER.
Drive belt surface flat
spots
S
Inspect and replace as needed.
Drive chain loose
S
S
Inspect and adjust (or replace).
SEE YOUR DEALER.
Drive chain worn,
sprocket teeth broken
Poor low RPM
performance
Worn drive belt
S
S
Inspect and replace as needed.
SEE YOUR DEALER.
Excessive belt/sheave
clearance
Loose torque stop
Sticky clutch
S
S
S
S
Inspect and adjust.
SEE YOUR DEALER.
Poor fuel quality
Seized engine
Use premium fuel (91 octane or higher)
Engine doesn’t
turn
SEE YOUR DEALER. Seizure is a re-
sult of poor lubrication, inadequate fuel
supply, broken parts or improper cool-
ing.
Hydrostatic lock
S
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 lo-
cated on the lower crankcase for emer-
gency draining.
119
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Engine turns
but fails to start
Faulty ignition
S
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
S
S
Check the fuel tank level and fill with
correct fuel.
Ice may be in the fuel line, filter or
pump. Add isopropyl alcohol to the
fuel system.
Poor engine
compression
S
Mixture is too lean. This indicates a ma-
jor engine problem that must be repaired
before the engine is run. SEE YOUR
DEALER.
Engine lacks
power
Fouled or defective
spark plug
S
S
Replace the plug.
Fuel filter (loss of
high RPM power)
SEE YOUR DEALER.
Incorrect clutching
Faulty plug(s)
Fuel System
S
S
S
SEE YOUR DEALER.
Change plug(s).
Engine
continually
backfires
Dirt or ice may be in the fuel system
(deicer should be added to non-ethanol
fuel at all times for assurance against
fuel line icing).
Incorrect throttle free-
play or faulty switch
S
S
SEE YOUR DEALER
Engine requires Poor gasoline or not
Replace with fresh winter fuel.
more than
enough fuel getting to
normal pulls to engine
start
Engine back-
Spark plug wires may
S
Reinstall spark plug wires to the corre-
sponding cylinder.
fires but fails to be on wrong cylinder
start
120
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TROUBLESHOOTING
IQ Suspension Troubleshooting
Problem
Solution (perform only one change at a time)
Rear suspension
bottoms too easily
S
S
Adjust torsion spring preload to achieve proper static sag
(see page 44).
Change torsion spring to stiffer optional spring (see your
dealer).
S
S
Revalve rear track shock (see your dealer).
Rides too stiff in
rear
Check for binding suspension shafts and grease all pivot
points.
S
S
S
Adjust torsion spring preload to achieve proper static sag
(see page 44).
Change torsion spring to softer optional spring (see your
dealer).
Check for proper track tension (see page 107).
Machine darts from
side to side
S
S
S
S
S
S
Check ski alignment (see page 110).
Make sure spindles and all steering components turn freely.
Ensure skags are straight on skis.
Check rail slide/replace if worn (see page 112).
Install dual skags.
Set static sag (see page 44).
Front end pushes
Steering is heavy
S
S
S
S
Check for worn skags.
Set static sag (see page 44).
Install single skag (see your dealer).
Rotate RRSS to high position (see page 48).
S
S
S
S
Make sure spindles and all steering components turn freely.
Check ski alignment (see page 110).
Check skags and skis for damage.
Set static sag (see page 44).
121
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TROUBLESHOOTING
M-10 Suspension Troubleshooting
Problem
Solution (perform only one change at a time)
Rear suspension
bottoms too easily
S
S
Increase FRA position (see page 50).
Install appropriate optional center retainer on rear track shock
(see page 51).
S
S
Increase front track shock coil spring preload.
Revalve rear track shock compression damping (see your
dealer).
S
Check track tension (see page 107).
Rides too stiff in
rear
S
S
Decrease FRA position (see page 50).
Install appropriate optional center retainer on rear track shock
(see page 51).
S
S
Decrease front track shock coil spring preload.
Revalve rear track shock compression damping (see your
dealer).
S
Check track tension (see page 107).
Machine darts from
side to side
S
S
S
Make sure skis are aligned properly.
Make sure spindles and all steering components turn freely.
Check for excessive play in steering assembly (see your deal-
er).
S
S
S
Make sure skags are straight on skis.
Set static sag (see page 44).
Install dual skags.
Front end pushes
Steering is heavy
S
S
Check for worn skags
Check for binding suspension shafts and grease all pivot
points.
Shorten front limiter strap.
Install single skags (see your dealer).
S
S
S
S
S
S
Check ski alignment.
Make sure spindles and all steering components turn freely.
Check skags and skis for damage.
Decrease IFS preload.
122
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TROUBLESHOOTING
Belt Troubleshooting
Belt Wear/Burn Diagnosis
Solutions
Causes
Driving at low RPM
S
Drive at higher RPMs. Gear the machine down. Check
belt deflection.
Insufficient warm-up
Towing at low RPM
S
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.
S
S
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
between track and
tunnel
S
Warm the engine at least five minutes. Take the drive belt
off the machine in extremely cold weather and warm it
up. Break machine loose from the snow.
Poor engine
performance
S
S
Check for fouled plugs or water, ice, or dirt in the gas
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
S
S
Inspect clutch components. See your dealer.
Use fast, aggressive throttle to engage clutch.
Slow, easy clutch en-
gagement
123
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WARRANTY
Service And Warranty Information
Obtaining Service and Warranty Assistance
Read and understand the service data and the Polaris warranty
information contained in this manual. Contact your Polaris dealer for
replacement parts, service or warranty. Your dealer receives frequent
updates on changes, modifications and tips on snowmobile
maintenance, which may supersede information contained in this
manual. Your dealer is also familiar with Polaris policies and
procedures and will be happy to assist you.
When contacting us about parts, service, or warranty, always provide
the following information:
1. Serial number 5. Details of trouble experienced
2. Model number 6. Length of time and conditions of operation
3. Dealer name
7. Previous correspondence
4. Date of purchase
Use the page provided near the front of your Owner’s Manual to record
the identification numbers of your snowmobile and its engine.
Polaris Customer Service
United States: 1-763-417-8650
Canada: 1-204-925-7100
Polaris Anti-Theft System
The Polaris anti-theft system (PATS) monitoring program is designed
to aid owners of registered snowmobiles in recovery of stolen
machines.
Administration
1. Polaris snowmobile owner reports theft.
A. In addition to notifying the proper law enforcement offi-
cials, the owner must call Polaris Customer Service.
B. Owners must provide their name, address, telephone num-
ber and the model and serial number of stolen machines.
2. Polaris warranty will provide all dealerships with a monthly
updated list of all stolen units to further monitor thefts.
3. Polaris warranty will aid in notifying the proper owner when a unit
is recovered.
124
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WARRANTY
Limited Warranty
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-
ITED WARRANTY on all components of the Polaris snowmobile against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. The warranty begins on
the date of purchase. This warranty is transferrable to another consumer, during the war-
ranty period, through a Polaris dealer.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and setup of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
setup will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures not caused by a defect in material or workmanship.
The warranty does not cover accidental damage, normal wear and tear, abuse or improper
handling. The warranty also does not cover any snowmobile that has been structurally
altered, neglected, improperly maintained, used for racing or used for purposes other
than for which it was manufactured. The warranty does not cover any damages that oc-
cur during trailer transit or as a result of unauthorized service or parts. In addition, this
warranty does not cover physical damage to paint or finish, stress cracks, tearing or punc-
turing of upholstery material, corrosion or defects in parts, components or the snowmo-
bile due to fire, explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,
repair or replacement of any defective materials, or components or products. THE REM-
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEG-
LIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-
sion or limitation of incidental or consequential damages or implied warranties, so the
above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
125
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-
LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations
on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controlling state law.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris snowmobiles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (The cost of transportation to
and from the dealer is YOUR responsibility). Polaris recommends that you use your
original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Your dealer will contact the
appropriate personnel at Polaris if additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
126
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WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested by
a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre--
Delivery Inspection, perform all applicable service bulletins and have the consumer sign
the PDI form prior to delivery may void the warranty. Failure to provide proof of re-
quired periodic maintenance upon request may result in denial of warranty coverage. Use
of the recommended Polaris products for lubrication and maintenance as directed by the
Owner’s manual is highly recommended. Should a failure occur during the warranty
period resulting from the use of non-recommended products, warranty coverage may be
denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty con-
sideration if the failure was due to wear or not the direct result of a defect:
Skis
Tracks
Ski wear rods
Slide rails
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered “consumable,” meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Filters
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Fuel
Sealants
Hotel fees
Towing charges
Mileage
Meals
Shipping/ handling fees
Product pick-up/delivery
Rentals/Loss of product use Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper en-
gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or
contamination; operator error or abuse; improper component alignment, tension, adjust-
ment or altitude compensation; failure due to snow, water, dirt or other foreign substance
ingestion/contamination; improper maintenance; modified components; use of aftermar-
ket components resulting in failure; unauthorized repairs; repairs made after the warranty
period expires or by an unauthorized repair center; use of the product in competition or
for commercial purposes. Warranty will not apply to any product which has been dam-
aged by abuse, accident, fire or any other casualty not determined a defect of materials or
workmanship.
127
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WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused
snowmobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is
transferable 120 days after the original purchase date, free of charge, through any Polaris
snowmobile dealer. Coverage on Snow Check units is automatic. Although you do not
receive a warranty card, your dealership should have printed a copy of the warranty
registration form. This form is your proof of warranty.
Consumer Exclusions
S
Each repair visit after the first twelve months of standard warranty coverage is subject
to a $50 deductible.
S
The free Second Year Engine Service Contract applies to the first 5,000 miles or two
(2) calendar years from date of purchase, whichever comes first. Tampering with the
odometer shall void all warranties/service contracts. No extensions to coverage under
this engine service contract can be given. Used snowmobiles are not eligible under
this program.
S
Snowmobiles used for commercial purposes or for racing are excluded from cover-
age.
Coverage
Coverage for second year engine failures due to defects in materials and workmanship
will be determined by Polaris in its sole discretion. Coverage is automatic with no
additional paperwork required. The free Second Year Engine Service Contract is subject
to a $50 deductible per visit. Regular, documented service maintenance visits are
required to validate this warranty.
A partial list of items excluded from coverage includes:
S
S
S
S
S
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.
Damage caused by the failure of other components of the snowmobile.
Failures caused by improper fuel or oil.
Piston seizures, unless caused by a defective engine component.
Failures caused due to improper adjustments.
S Failure due to unauthorized service.
S
Failures due to lack of service as required in the owner’s manual or Polaris updates.
This includes off-season storage as listed in the owner’s manual.
S
S
Failure due to use of unauthorized parts or modifications.
Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and
exhaust manifolds excluding paint coverage.
S
S
Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring
and other electrical components are excluded from coverage.
Cooling system coverage is limited to the water pump assembly and components, fan,
fan bearings, temperature sensor, gasket and seals.
S
S
Non wear related throttle body parts are covered. The fuel pump is covered.
Clutches and related clutch parts, including but not limited to, the drive belt, are ex-
cluded from coverage.
S
S
Electrical components are excluded from coverage.
Gearcases and transmissions are excluded from coverage.
128
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WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to per-
form the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance (see page 124).
129
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WARRANTY
Snowmobile Engine Emissions Limited Warranty
This snowmobile engine emissions limited warranty is in addition to the Polaris standard
limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first
purchased, this emissions--certified snowmobile engine meets current U.S. Environmental
Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051,
1065 and 1068.
Polaris warrants that the engine is free from defects in materials and workmanship that
would cause it to fail to meet these regulations. The warranty period for this emissions certi-
fied snowmobile engine starts on the date when the engine is first purchased and continues
for 4000 kilometers (2485 miles) of vehicle travel, 200 hours of operation, or 30 calendar
months, whichever comes first.
This engine emissions limited warranty covers the parts and labor charges for repair or re-
placement of defective parts that are covered by this warranty. This includes components
whose failure increases the snowmobile engine’s emissions. To the extent they are present
on your snowmobile engine, this includes electronic controls, fuel injection components,
exhaust--gas recirculation system components, and aftertreatment system components. Re-
placing or repairing other components not covered by this warranty is the responsibility of
the snowmobile owner.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option
of Polaris, repair or replacement of any defective materials, components or products.
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-
TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WAR-
RANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIM-
ITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. PO-
LARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS
WARRANTY.
130
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WARRANTY
Snowmobile Engine Emissions Limited Warranty
Some states do not allow limitations on how long an implied warranty lasts, so the above
limitation may not apply if it is inconsistent with the controlling state law. This limited war-
ranty excludes failures not caused by a defect in material or workmanship. This limited war-
ranty does not cover damage due to accidents, abuse or improper handling, maintenance or
use. This limited warranty also does not cover any engine that has been structurally altered,
or any engine that has been used in racing competition. This limited warranty also does not
cover physical damage, corrosion or defects caused by fire, explosions or other similar
causes beyond the control of Polaris.
Owners are responsible for performing the scheduled maintenance identified in the owner’s
manual. Polaris can deny an emissions warranty claim if any specified critical emissions--re-
lated maintenance is not performed. Performance of other scheduled maintenance is strong-
ly recommended, but is not necessary to keep the emissions--related warranty valid.
Any qualified repair shop or qualified person may maintain, replace, or repair the emission
control devices or systems on your snowmobile. Polaris recommends that you contact an
authorized Polaris dealer to perform any service that may be necessary.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with
emission controls is prohibited by federal law and may result in civil penalties.
131
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MAINTENANCE LOG
Present this section of your manual to your dealer each time your
snowmobile is serviced. This will provide you and future owners with
an accurate log of maintenance and services performed on the
snowmobile.
DATE
MILES (KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
132
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MAINTENANCE LOG
DATE
MILES (KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
133
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INDEX
A
D
Access Panel . . . . . . . . . . . . . . . . . . . 28
Accessories . . . . . . . . . . . . . . . . . . . . 55
Adjustable Headlights . . . . . . . . . . . . 28
Avalanches . . . . . . . . . . . . . . . . . . . . 14
Drive Chain Tension . . . . . . . . . . . . . 93
Driver Awareness . . . . . . . . . . . . . . . 13
Driveshaft Bearing . . . . . . . . . . . . . . 83
Driving Downhill . . . . . . . . . . . . . . . 15
Driving in Hilly Terrain . . . . . . . . . . 16
Driving on Slippery Surfaces . . . . . . 15
Driving Responsibly . . . . . . . . . . . . . 19
B
Bearings . . . . . . . . . . . . . . . . . . . . . 115
Before Starting the Engine . . . . . . 59-62
Belt Troubleshooting . . . . . . . . . . . 123
Bleeding the Cooling System . . . . . . 92
Bleeding the Hydraulic Brake System 97
Brake Components . . . . . . . . . . . . . . 95
Brake Fluid . . . . . . . . . . . . . . . . . . . . 96
Brake Lever Travel . . . . . . . . . . . . . . 60
Brake, Park . . . . . . . . . . . . . . . . . . . . 61
Brakes . . . . . . . . . . . . . . . . . . . . . . 94-97
Bulb Replacement . . . . . . . . . . . . . . . 98
E
Electrical Connections . . . . . . . . . . 116
Electronic Reverse . . . . . . . . . . . . . . 74
Emergency Starting . . . . . . . . . . . . . . 73
Emergency Stopping . . . . . . . . . . . . . 73
Engine Break-In . . . . . . . . . . . . . . . . 65
Engine Protection . . . . . . . . . . . . . . 115
Engine Safety . . . . . . . . . . . . . . . . . . .
9
Engine Stop Switch . . . . . . . . . . 63, 71
Engine Troubleshooting . . . . . . 118-120
Excessive Speed . . . . . . . . . . . . . . . . 12
Exhaust System . . . . . . . . . . . . . . . . . 90
C
Chaincase Oil . . . . . . . . . . . . . . . . 84-85
Cleaning and Preservation . . . . . . . . 114
Clutch Alignment . . . . . . . . . . . . . . 100
Clutch and Drive System . . . . . . . . 115
Clutch Cover . . . . . . . . . . . . . . . . . . . 21
Clutch System . . . . . . . . . . . . . . 100-103
Clutches . . . . . . . . . . . . . . . . . . . . . . 17
Cold Weather Drive-Away . . . . . . . . 17
Controls and Linkage . . . . . . . . . . . 114
Coolant . . . . . . . . . . . . . . . . . . . . . . . 90
Coolant Level . . . . . . . . . . . . . . . . . . 91
Cooling System . . . . . . . . . . . . . . 90-92
Coupling . . . . . . . . . . . . . . . . . . . . 46-47
Coupling, Front To Rear . . . . . . . . . . 46
Coupling, Rear To Front . . . . . . . . . . 47
F
Fall Tune-Up . . . . . . . . . . . . . . . . . . 104
Flushing the Cooling System . . . . . . 91
FRA Position, M10 . . . . . . . . . . . . . . 50
Front Rear Scissor Stop . . . . . . . . . . . 46
Front Springs . . . . . . . . . . . . . . . . . . 42
Fuel . . . . . . . . . . . . . . . . . . . . . . . . 68-69
Fuel Injectors . . . . . . . . . . . . . . . . . . 88
Fuel Level . . . . . . . . . . . . . . . . . . . . . 69
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 88
Fuel Pump . . . . . . . . . . . . . . . . . . . . 88
Fuel System Deicers . . . . . . . . . . . . . 69
G
D
Gauge Cleaning . . . . . . . . . . . . . . . . 38
Daily Storage . . . . . . . . . . . . . . . . . . 75
Detonation Elimination Technology . 29
Digital Display Identification . . . . . . 30
Disabled Operators . . . . . . . . . . . . . . 11
Drive Belt . . . . . . . . . . . . . . . . . . . . . 17
Drive Belt Adjustment . . . . . . . . . . 103
Drive Belt Condition . . . . . . . . . . . . 101
Drive Belt Deflection . . . . . . . . . . . 103
Drive Belt Installation . . . . . . . . . . . 102
Drive Belt Removal . . . . . . . . . . . . 101
H
Halogen Bulbs . . . . . . . . . . . . . . . . . 98
Handlebar Adjustments . . . . . . . . . . . 54
Handlebar Angle . . . . . . . . . . . . . . . . 54
Handlebar Position . . . . . . . . . . . . . . 54
Headlights . . . . . . . . . . . . . . . . . . . . . 28
High Temperature Indicator . . . . . . . 91
Hydraulic Brake Inspection . . . . . . . . 94
134
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INDEX
I
R
Ice and Snow Build-up . . . . . . . . . . . 15
IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 39
IFS Adjustment Options . . . . . . . . . . 39
IFS Components . . . . . . . . . . . . . . . . 39
Inadequate Snow Conditions . . . . . . 18
Independent Front Suspension . . . . . 39
Instrumentation . . . . . . . . . . . . . . . 30-38
Intake Filter . . . . . . . . . . . . . . . . . . . . 88
Intake Silencer . . . . . . . . . . . . . . . . . 17
Rear Rear Scissor Stop . . . . . . . . . . . 47
Rear Spring Preload, M10 . . . . . . . . . 51
Recommended Maintenance Program 78
Reverse . . . . . . . . . . . . . . . . . . . . . . . 23
Reverse, Electronic . . . . . . . . . . . . . . 74
Rider Capacity . . . . . . . . . . . . . . . . . 12
RIDER SELECT
Adjustable Steering System . . . . 27
Riding Apparel . . . . . . . . . . . . . . . . . 11
Riding Position . . . . . . . . . . . . . . . . . 10
L
S
Lever Travel . . . . . . . . . . . . . . . . . . . 95
Lighting Check . . . . . . . . . . . . . . . . . 63
Lights . . . . . . . . . . . . . . . . . . . . . . 98-99
Low Oil Level . . . . . . . . . . . . . . . . . . 67
Lubrication . . . . . . . . . . . . . . . . . . 82-85
Safety Decals and Locations . . . . . 21-24
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Sag/Ride Height, M10 . . . . . . . . . 49-51
Scissor Stop . . . . . . . . . . . . . . . . . 46-47
Seat Storage Compartment . . . . . . . . 28
Second Year Engine Service Contract 128
Service And Warranty Information . 124
Shock Absorber Components . . . . . . 40
Shock Spring Preload, Front . . . . . . . 41
Shock Valving . . . . . . . . . . . . . . . . . . 42
Shock, PPS . . . . . . . . . . . . . . . . . . . . 45
Shocks, Rear . . . . . . . . . . . . . . . . . . . 45
M
Maintenance Interval Table . . . . . . 79-81
Maintenance Log . . . . . . . . . . . . . . 132
Maneuverability . . . . . . . . . . . . . . . . 17
MFD Battery Replacement . . . . . . . . 37
MFD Component Identification . . . . 30
MFD Digital Display Programs . . 32-36
MFD Settings . . . . . . . . . . . . . . . . . . 31
Mirror Adjustment . . . . . . . . . . . . . . 63
Signal Words . . . . . . . . . . . . . . . . . . . .
7
Skag Replacement . . . . . . . . . . . . . . 111
Ski Alignment . . . . . . . . . . . . . . . . . 110
Ski Pressure, M10 . . . . . . . . . . . . . 52-53
Ski Skags . . . . . . . . . . . . . . . . . . . . 111
Slide Rail and Track Cooling . . . . . . 65
Slider Wear . . . . . . . . . . . . . . . . . . . 112
Spark Plugs . . . . . . . . . . . . . . . . . . 86-87
Spring Preload . . . . . . . . . . . . . . . . . 44
Springs, Front . . . . . . . . . . . . . . . . . . 42
Start the Engine and Check . . . . . . . . 63
Starting the Engine . . . . . . . . . . . . . . 64
Starting, Emergency . . . . . . . . . . . . . 73
Steering Adjustment . . . . . . . . . . . . 109
Steering Inspection . . . . . . . . . . . . . 109
Steering System . . . . . . . . . 62, 109-111
Stopping . . . . . . . . . . . . . . . . . . . . . . 73
Storage . . . . . . . . . . . . . . . . 75, 114-116
Storage Compartment . . . . . . . . . . . . 28
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 89
Oil Injection System . . . . . . . . . . . . . 66
Oil Recommendations . . . . . . . . . . . . 66
Operation . . . . . . . . . . . . . . . . . . . 23-24
Operator Safety . . . . . . . . . . . . . . . . 7-20
P
Passenger . . . . . . . . . . . . . . . . . . . . . 22
PERC . . . . . . . . . . . . . . . . . . . . . . . . 74
Polaris Products . . . . . . . . . . . . . . . 117
Pre-Ride Checklist . . . . . . . . . . . . . . 58
Pre-Ride Suspension Inspection . . . 113
Pressure Cap . . . . . . . . . . . . . . . . . . . 21
135
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INDEX
S
T
Survival Preparation . . . . . . . . . . . . . 10
Suspension . . . . . . . . . . . . . . . . . . . 116
Suspension Coupling . . . . . . . . . . . . 46
Suspension Maintenance . . . . . . 112-113
Suspension Performance Tips . . . . . . 43
Suspension Troubleshooting, IQ . . . 121
Suspension Troubleshooting, M10 . 122
Suspension, Front . . . . . . . . . . . . . 39-42
Suspension, Rear, IQ . . . . . . . . . . . 43-48
Suspension, Rear, M10 . . . . . . . . . 49-53
Track . . . . . . . . . . . . . . . . . . . . . 22, 116
Track Alignment . . . . . . . . . . . . . . . 106
Track Cooling . . . . . . . . . . . . . . . . . . 65
Track Inspection . . . . . . . . . . . . 62, 105
Track Lubrication . . . . . . . . . . . . . . 105
Track Maintenance . . . . . . . . . . 105-108
Track Safety . . . . . . . . . . . . . . . . . . . .
9
Track Tension . . . . . . . . . . . . . . 107-108
Track Tension Data . . . . . . . . . . . . . 107
Track Warm-Up . . . . . . . . . . . . . . . . 70
Traction Products . . . . . . . . . . . . . 56-57
Transporting the Snowmobile . . . . . 116
Symbols . . . . . . . . . . . . . . . . . . . . . . .
7
T
V
Taillight/Brakelight Replacement . . . 99
Tether Switch . . . . . . . . . . . . . . . . . . 63
Throttle Cable . . . . . . . . . . . . . . . . . . 83
Throttle Lever . . . . . . . . . . . . . . . . . . 72
Throttle Safety Switch . . . . . . . . . . . 71
Tool Kit . . . . . . . . . . . . . . . . . . . . . . 104
Torque Stop . . . . . . . . . . . . . . . . . . 103
Torsion Spring Tension . . . . . . . . . . . 45
Towing . . . . . . . . . . . . . . . . . . . . . . . 75
Variable Exhaust System . . . . . . . . . . 66
Vehicle Identification Numbers . . . . . .
6
W
Warning Labels . . . . . . . . . . . . . . . 21-24
Wear Strips . . . . . . . . . . . . . . . . . . . . 57
Weight Transfer During Acceleration 48
Windchill/Temperature Charts . . . . . . 20
136
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