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WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a Factory Certified Master Service Dealer (MSD)
Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2007 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2008 FS IQ Touring/FST IQ Touring/IQ Cruiser Owner’s Manual P/N 9921087
2
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 54
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 74
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
This section defines your role, and your dealer’s role, in your snowmo-
bile’s regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 151
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 152
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 168
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3
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4
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INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient ref-
erence. It should remain with the snowmobile when the snowmobile is
sold.
Some of the illustrations and photos used in this manual are general rep-
resentations. 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.
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.
5
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INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education cam-
paign. We encourage state and provincial governments across the snow-
belt 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 pro-
tect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE 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.
6
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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.
Vehicle Model Number: ___________________________________________________
Tunnel VIN: _____________________________________________________________
(lower right side of the tunnel)
Engine Serial Number (on valve cover): _______________________________________
Key Number: ___________________________________________________________
7
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, 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.
8
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SAFETY
Operator Safety
Follow the recommended maintenance program outlined beginning on
page 99 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.
9
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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 ser-
vice and alignment procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Turn off the igni-
tion, raise the hood, make the adjustment, secure shields and guards,
secure the hood, and then restart the engine to check its operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving parts of an
engine. Always stop the engine before attempting adjustments.
10
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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 many conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING
Improper riding position may reduce control and could result in serious injury
or death. Always ride in a position that allows for control of your vehicle.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone. If
it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the condi-
tions you may encounter. Such equipment may include, but is not lim-
ited to: extra clothing, a sleeping bag, a flashlight, food and water, a
signaling mirror, a means of building a fire, and a two-way radio or cel-
lular telephone.
Always carry the owner’s manual on your snowmobile. For added pro-
tection, purchase and carry the following items on your snowmobile as
well:
• Spare Drive Belt
• Extra Set of Spark Plugs
• Tow Rope
• Winter Survival Kit
• Trail Map
• First Aid Kit
• Tool Kit
• Extra Oil
• Fuel Deicer
11
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SAFETY
Operator Safety
Riding Apparel
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
4
E
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
051039
0006.31
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Clothing
Be prepared, be warm and be com-
fortable when riding. Be aware of
the weather forecast, especially the
windchill, and dress accordingly.
See the chart on page 23.
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 pro-
tection.
12
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SAFETY
Operator Safety
Rider Capacity
Driving 1-Up - Some Polaris snowmobiles are designed for a single
rider only. A decal on the console of these models indicates single rider
operation.
Driving 2-Up - Some Polaris snowmobiles are designed for up to two
riders. A decal on the hood of these models indicates that the vehicle is
designed for one operator and one passenger only.
WARNING
Control becomes more difficult with two people on board. More space is
required to make turns, and longer distances are needed for stopping. Make
sure the passenger remains seated behind the driver, facing forward, with
both feet placed firmly on the running boards. Slow down and avoid “jumping”
your snowmobile.
Snowmobiles designed for two riders should never be operated with
more than two people on board. When traveling with a passenger, it’s
the driver’s responsibility to operate the snowmobile safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are necessary
for stopping.
13
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SAFETY
Operator Safety
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills.
WARNING
Operators with cognitive or physical disabilities have an increased risk of loss
of control, which could result in serious injury or death. Do not allow disabled
persons to operate this vehicle.
Cargo Overload
Too much weight on the rear of the machine may reduce your ability to
steer. Do not exceed carrier and rack weight limits, and do not allow a
passenger to sit on the seat back or the cargo carrier.
14
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SAFETY
Operator Safety
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious injury or death.
Always reduce speed when driving at night or in inclement weather.
Always observe all state and local laws governing snowmobile opera-
tion and speed limits. Always be alert and pay attention to the trail
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in
two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t over-drive your headlight beam.
Always be able to bring your snowmobile to a stop in the distance illu-
minated by the headlight.
15
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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 snowmobile 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.
R R
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.
16
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly trained and equipped before
traveling in mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• Make sure each person is equipped
with a shovel, probe and avalanche
beacon.
You don’t have to be snowmobiling on a
slope for an avalanche to occur. Be aware
that all of the snow is connected. You may be riding on a flat slope or
snow covered road, but if the snowpack above is unstable enough you
can trigger an avalanche on a steeper slope above you. Always be aware
of snow conditions above you as you travel in mountainous terrain.
Before riding in mountainous terrain, call or log on to your local ava-
lanche advisory to get current weather and snow stability information.
For more information about avalanche training and avalanche condi-
tions, contact local law enforcement in your area, or visit the American
and Canadian online avalanche centers at www.avalanche.org.
17
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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 snowmobile,
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 Downhill
When riding downhill, shift your weight to the rear of the snowmobile
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
snowmobile 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.
18
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SAFETY
Operator Safety
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on slippery sur-
faces. 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 in Hilly Terrain
WARNING
Climbing a hill or crossing the face of a slope may result in loss of balance
and snowmobile rollover, 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 snowmobile to
maintain proper balance and avoid possible rollover.
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 snowmobile 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 snowmobile, pull the rear of the snowmobile
around and point the front end and skis downhill. Remount the snowmo-
bile, restart the engine, release the parking brake, and descend the hill
carefully.
19
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SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may result
in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is dynami-
cally balanced before installation. Any tampering may disrupt this preci-
sion balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, espe-
cially overnight, always make sure the skis and track are loosened from
ice and snow before attempting to drive. Apply the throttle with enough
authority to put the snowmobile into motion, but always operate within
safety limits and, on 2-up machines, with respect for a passenger.
Maneuverability
While much control and maneuverability is achieved through the steer-
ing system and skis, maximum control is achieved by the shifting of
your body weight. Maneuverability will change for lighter operators or
snowmobiles designed to carry a load or a passenger.
20
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SAFETY
Operator Safety
Inadequate Snow Conditions
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 snowmobile. Driving in too
little snow will result in excessive wear and damage to the slide rail,
track and/or engine.
WARNING
Inadequate cooling and lubrication will lead to overheating of the slide rail
and track, causing premature wear, damage and failure, which can result in
serious injury. Reduce speeds and frequently drive into fresh snow to allow
adequate cooling and polishing of the slide rail and track surfaces. Avoid
operating for prolonged periods on ice, hard-packed surfaces or roads.
Operating in Deep Snow
If the snowmobile becomes stuck in snow, clear the running board area
of snow, then step down the snow in front of the snowmobile so that
when the throttle is opened, the snowmobile will be able to climb up and
over the snow.
21
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SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile condi-
tions may become dangerous if operators drive improperly. If you’re
new to snowmobiling, acquaint yourself with the machine and with
what it will and won’t do under various conditions. Even seasoned driv-
ers should spend some time getting the feel for a machine before
attempting ambitious maneuvers.
• A snowmobile depends on the rider’s body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
• Before allowing someone else to use your snowmobile, know the
extent of their operating skills. Check to see if they’ve taken a snow-
mobile safety course and have an operator’s certificate. For their pro-
tection, as well as yours, make sure they take a snowmobile safety
course. Everyone can benefit from the course.
• Don't "jump" your snowmobile over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. The seat and
suspension of your snowmobile have been designed to provide pro-
tection under normal riding conditions. Your snowmobile is not
intended for this kind of use.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive defen-
sively to avoid accidents.
• Remove the key from the ignition when you leave the snowmobile
unattended.
22
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when tem-
peratures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
in
Actual Thermometer Reading (_F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
Equivalent Temperature (_F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63
40 35 30 25 20 15 10
5
0
MPH
Calm 40 35 30 25 20 15 10
5
0
5
36 31 25 19 13
7
3
0
1
10
15
20
25
30
35
40
45
50
55
60
34 27 21 15
32 25 19 13
30 24 17 11
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
29 23 16
28 22 15
28 21 14
27 20 13
26 19 12
26 19 12
25 18 11
25 17 10
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
Frostbite in >> 30 min. 10 min. 5 min.
WIND CHILL CHART (°C)
Wind
Speed
in
Actual Thermometer Reading (_C)
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Equivalent Temperature (_C)
KPH
Calm
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
-
-7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57
16
24
32
40
48
56
64
72
80
88
96
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
Frostbite in >> 30 min. 10 min. 5 min.
23
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your protec-
tion. Read and follow the instructions of the decals and other warnings
on the snowmobile carefully. If any of the decals depicted in this manual
differ from the decals on your snowmobile, always read and follow the
instructions of the decals on the snowmobile.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found under the hood on the clutch cover:
WARNING
Do not operate with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with plenum/belt guard removed.
Never run engine with drive belt removed.
Never service clutches yourself. See your dealer.
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of appli-
cable liquid cooled models:
WARNING
Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI
24
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SAFETY
Safety Decals and Locations
“No Passenger” Warning
Snowmobiles designed for a single
rider only have a warning decal on
the left console:
WARNING
“No Passenger”
This vehicle is designed for
operator only.
Warning or
“One Passenger”
Warning
“NO PASSENGER”
Passenger Warning
Snowmobiles designed for an
operator and one passenger have a
warning decal on the left console.
For more information on operating
with a passenger, see page 13.
WARNING
This vehicle is designed for
operator and “ONE” passenger only.
Track Warning
WARNING
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.
Track Warning
25
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SAFETY
Safety Decals and Locations
Reverse Warning
Operation
Warning
Reverse Warning
Polaris snowmobiles equipped with electric reverse and will have this
decal on the console:
WARNING
Reverse operation, even at low speeds, can cause loss of control
resulting in serious injury or death. To avoid loss of control,
always:
• Look behind before and while backing up.
• Avoid sharp turns.
• Shift to or from reverse only when stopped.
• Apply throttle slowly.
NOTE: For more information, see Owner's Manual.
If electric reverse:
• Machine stopped and engine at idle, push yellow button on LH con-
trol to reverse. Flashing light on dash indicates reverse operation.
• Push button again to return to forward.
26
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SAFETY
Safety Decals and Locations
Operation Warning
An operation warning decal is present on the console of all Polaris
snowmobiles:
WARNING
• To avoid serious injury or death, read and understand all warnings
and the Owner’s Manual before operation. If manual is missing, con-
tact a Polaris dealer for a replacement.
• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.
• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.
• Never consume alcohol or drugs before or while operating this vehi-
cle.
• In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.
• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
• This vehicle is designed for adult use only. Check local laws for age
requirements.
• When operating with a passenger (on approved models only),
reduce speed and allow extra space for steering and stopping. A
passenger reduces your ability to control the vehicle.
• When operating on hard-packed snow, ice, or when crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or stop.
• To maintain vehicle control on ice or hard-packed surfaces, you
should have a proper balance of ski carbides to track studs. See
Owner’s Manual for proper use of traction products.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• Before starting the engine, check throttle, brake, and steering for
proper operation. Make sure hood is latched. Be seated and in posi-
tion to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when
refueling.
27
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FEATURES
6
7
5
4
3
2
1
1. Nosepan
2. Skis
3. Front Bumper (do not use for
pulling or dragging the
snowmobile)
10
11
9
12
8
13
4. Hood
5. Headlight
6. Windshield
7. Storage Compartment or
14
Cargo Bag
8. Operator Seat
9. Passenger Seat
10. Backrest
11. Passenger Grab Handle
12. Grab Handle Heater Switch
13. Taillights
15
16
17
14. Rear Bumper
15. Snow Flap
16. Track
17. Suspension
28
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FEATURES
1. MFD Display
2. Mirrors
1
3. Rider Selectt
4. Fuel Filler Cap
5. Handlebar
6. Hood Hold Down
Straps
7. Handlebar Grip
Warmer Switch
8. Thumbwarmer Switch
6
9. Electronic Reverse
Button
10. MFD Control
11. Headlight Dimmer
5
4
1
3
Switch
12. Parking Brake Lock
13. Brake Lever
14. Engine Stop Switch
15. Throttle Control
16. M-10 ACE Suspension
Adjustment Switch
(Cruiser)
7
8
9
17. Ignition Switch
10
12
13
11
14
15
17
16
29
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FEATURES
Backrest
The backrest is adjustable for either
operator or passenger use. See page
32 for passenger seat installation
instructions.
Raise/Lower
1. Loosen the upper adjustment
knobs to raise or lower the
backrest.
2. Loosen the lower adjustment
knobs to move the backrest for-
ward for operator use or rear-
ward for passenger use.
Operator/Passenger
3. Always tighten the knobs
securely after adjusting.
M-10 ACE Suspension Adjustment Switch
A switch on the console (above the
ignition switch) allows you to adjust
the M-10 ACE suspension with the
MFD control switch. See page 69 for
instructions.
ACE Suspension
Adjustment Switch
30
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FEATURES
Adjustable Headlights
Move the adjuster to the left to lower the
headlight beam.
Move the adjuster to the right to raise the
headlight beam.
Radiator Compartment
Access Panel
The access panel is provided for cleaning
debris from the radiator.
+
Cargo Bag (Touring)
The cargo bag is secured to the rear of
the tunnel with straps. The cargo bag
and the passenger seat are removable to
provide open storage for transporting
larger items. The maximum weight
capacity for the cargo area is 30 lbs.
(14 kg). Always secure cargo before
operating. Do not exceed the weight
limit. Do not allow a passenger to sit on
the seat back or the cargo area.
Cargo Bag
1. Push down on the seat latch lever,
which is located at the lower rear
of the passenger seat.
2. Lift up the seat and remove it from
the chassis.
Seat Latch
3. Reverse the procedure to reinstall
the seat. Press down firmly on both
sides of the seat to engage the
latch. Verify that the latch is
engaged by firmly pulling the seat
upward.
31
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FEATURES
Trunk/Passenger Seat/Cargo Bag (Cruiser)
The trunk cover is removable to
allow installation of the passenger
seat and cargo bag. The maximum
weight capacity for the cargo car-
rier is 30 lbs. (14 kg). Always
secure cargo before operating. Do
not exceed the carrier weight limit.
Do not allow a passenger to sit on
the seat back or the cargo area.
1. Adjust the backrest to the for-
ward (operator) position. See
page 30.
2. Release the trunk cover latch.
3. Lift the trunk assembly
upward and rearward to
remove it.
4. Install the passenger seat
securely.
5. Install the cargo bag and
secure the straps to the cargo
carrier sides.
6. Adjust the backrest to the rear
(passenger) position.
32
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FEATURES
Passenger Grab Handle
On some models the position of the
passenger grab handles can be
adjusted for rider preference.
Knob
Assembly
1. Unscrew and remove the knob
assemblies that secure the grab
handles.
2. Reposition the grab handles to
one of the three available posi-
tions on the grab handle tube
between the operator seat and the
passenger seat.
3. Reinstall the knob assemblies and
tighten securely.
12-Volt DC Outlet
If equipped, use the outlet to power
a global positioning sensor (GPS),
heated helmet shield, utility light,
cell phone or other accessories.
The 12-volt DC outlet is installed
in the recoil pocket next to the
right hood hold-down. If you
install an accessory outlet on your
model, always install it in the
recoil pocket. The fuel filter is
installed in the upper console area.
Do not install an outlet on the
upper console.
12-Volt DC Outlet
WARNING
Serious injury could occur if sparks ignite a fuel supply. Do not install an
accessory 12-volt DC outlet on the upper console. Install the outlet in the
recoil pocket.
33
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FEATURES
RIDER SELECT Adjustable Steering System
The RIDER SELECT adjustable steering system (if equipped) allows
you to adjust the handlebar position to fit your style of riding. Some
models have five (5) adjustment positions. Other models have seven (7)
positions.
WARNING
If your snowmobile has five adjustment positions, do not remove the RIDER
SELECT lockout. Your Polaris snowmobile has been engineered for this
range of adjustability. Removing this lockout and using RIDER SELECT posi-
tion 6 or 7 will result in the handlebars and brake lever contacting other com-
ponents and interfering with steering and braking. This could lead to loss of
control resulting in serious injury or death. Always be sure that the handle-
bars and brake lever do not contact any other snowmobile components at
any steering position AND at any RIDER SELECT position.
Do not use RIDER SELECT positions 6 or 7 unless riding conditions require
it. Operation in position 6 or 7 can reduce vehicle handling for other types of
riding and result in serious injury or death.
34
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FEATURES
RIDER SELECT Adjustable Steering System
Choosing the Best RIDER SELECT Position
Position
Riding Style
1
2
3
Relaxed Trail Riding
Rider weight is slightly behind the center
of the snowmobile for comfortable and
relaxed riding.
4
5
General Trail Riding, Boondocking,
Deep Snow Riding
Rider weight is centered on the snowmo-
bile, providing balance, comfort and con-
trol for both novice and experienced
riders. This is the recommended position
for most riding situations.
6
7
Snowcross/Steep Hill Climbing Only
Rider weight is ahead of the center of the
snowmobile, adding weight to the skis and
making the snowmobile heavier in the
front. These positions are ONLY for
snowcross and severe hill climbing.
35
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FEATURES
RIDER SELECT Adjustable Steering System
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.
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 mecha-
nism 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 con-
trol 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.
36
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FEATURES
Engine Management System
Malfunction Indicator Lamp (MIL)
Illuminated MIL
The MIL (Check Engine Indicator) will illuminate when a problem with
engine management system components is detected.
1. Turn the engine off and restart it. If the light goes off, continued
operation is permissible.
2. If the light illuminates again, determine whether engine RPM or
vehicle speed is limited, then check the charts on page 38 to identify
the cause.
NOTE: If you are unable to determine the cause of an illuminated MIL, please
see your Polaris dealer.
Flashing MIL (Turbo)
The MIL will flash if an error with the turbo boost regulation system is
detected.
CAUTION
If you are unable to determine and correct the cause of a flashing MIL or high
temperature indicator, serious engine damage may occur with continued
operation. See your Polaris dealer.
1. Verify that all electrical connections are secure.
2. Check battery voltage on the gauge, and install a new battery if volt-
age is low (see page 52).
3. Verify that engine temperature is within the recommended operating
range. See the Turbo Boost chart on page 38.
A flashing MIL may also be caused by damaged or disconnected hoses
between the turbocharger and wastegate solenoid pulse valve (located
on the engine side of the airbox) or between the wastegate actuator
(located under the turbocharger) and wastegate solenoid pulse valve. If
the hose has no damage and is not disconnected, see your dealer imme-
diately.
CAUTION
Serious engine damage may occur if the wastegate reference line is
removed or modified. DO NOT remove or modify the wastegate reference
line.
37
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FEATURES
Engine Management System
To protect the engine, the engine management system will limit engine
RPM, vehicle speed or turbo boost (if equipped) if the following condi-
tions are encountered. Under extreme overheating conditions, the sys-
tem will also stop the engine entirely to prevent engine damage.
Vehicle Speed is Limited
Cause
Function
Maximum Speed
MPH (km/h)
Result
Reverse is selected
Reverse
12 (19)
37 (59)
18 (29)
Engine will mis-
fire at higher
vehicle speed
Defective rollover switch Rollover
Throttle stuck, throttle
lever depressed
Throttle stuck, throttle
safety switch high
Maximum vehicle speed Max speed limiter
186 (299)
Engine Speed is Limited
Cause
Function
Maximum RPM
Result
Reverse is selected,
speed sensor error
Reverse
5300
Defective rollover
switch, speed sensor
error
Rollover
6000
5450
Engine will mis-
fire at higher
engine speed
Throttle stuck, throttle
lever depressed, speed safety switch high
sensor error
Throttle stuck, throttle
Throttle stuck, throttle
lever at idle position
Throttle stuck, throttle
safety switch low
2400
8800
2500
Maximum vehicle speed, Max speed limiter
speed sensor error
Reverse failure
Reverse
ECU cannot
determine if
reverse or for-
ward selected
Turbo Boost is Limited (Turbo)
Indication
Result
Illuminated High Temperature Indicator
Engine coolant temperature is at or below 122° F (50° C) OR
Engine coolant temperature is at or above 203° F (95° C)
Operator may feel
loss of power
Intake manifold air temperature is at or below 32° F (0° C) OR
Intake manifold air temperature is at or above 158° F (70° C)
Overboost condition occurs (Check Engine light will flash)
Fuel octane is too low (use the recommended fuel)
38
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FEATURES
Engine Management System
The engine management system is programmed to alert the rider when
coolant temperatures reach higher-than-normal levels. The system
responds by taking the following sequential steps to alert the rider.
1. The High Temperature Indicator on the MFD will flash.
To cool the engine, drive the snowmobile into soft snow so that it comes
into contact with the heat exchangers on the snowmobile. Alternately,
you can stop the snowmobile and pack snow or ice onto the heat
exchangers to bring the temperature of the engine down.
2. The High Temperature Indicator on the MFD will flash and the
engine will misfire or "stutter".
If you do not notice the flashing indicator on the MFD or do not suffi-
ciently cool the snowmobile, the engine will misfire to alert you to look
at the MFD and take action. Again, driving the snowmobile into soft
snow or packing snow onto the heat exchangers should cool the engine.
3. The engine will stop.
If the engine reaches an extreme temperature where damage becomes
possible, the system will stop the engine. This condition will occur only
after the system has taken both previous steps to alert the rider to the
extreme engine temperature. If the engine stops and you attempt to
restart it while before it has cooled sufficiently, the engine will restart
and run for two seconds but will immediately stop again.
NOTE: The engine management system will also turn the engine off if the
engine reaches an extreme temperature while idling.
39
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FEATURES
Knock Sensor (Turbo Models)
A knock sensor monitors the engine and responds to detonation by auto-
matically reducing the engine timing and adding fuel. This results in
decreased engine RPM and performance.
NOTE: Engine performance will be reduced if fuel with a lower octane than 91
is used. See fuel recommendations on page 89.
Effect
The knock sensor system prevents damage to the engine from detona-
tion 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.
Fail-Safe
The knock sensor 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 illuminate if the sensor fails or becomes dis-
connected.
40
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FEATURES
Instrumentation
MFD Component Identification
Item
2
1
1
2
3
4
5
6
7
Analog Gauge
Digital Gauge
Check Engine Indicator
High Temp Indicator
Brake Indicator
Reverse Indicator
High Beam Indicator
3
7
6
4
5
Digital Display Identification
Item
1
RPM or Speed
Altitude (if equipped)
Service Interval
1
2
2
Electrical System Voltage
Level (all models) and M-10
ACE Suspension Adjustment
(RIDE) (Cruiser only)
3
4
MAX - Maximum MPH/
KPH or RPM
MPH - Miles per hour
KPH - Kilometers per hour
RPM - Engine crankshaft
revolutions per
minute
Air Temp (if equipped)
Engine Temp
Degrees Celsius
Degrees Fahrenheit
7
5
6
5
6
Miles/Kilometers
4
Hours
3
Trip 1/Trip 2/Trip F
Service Label
Altitude Label
7
Fuel Level (FS) or Turbo Boost
(Turbo models)
41
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FEATURES
Instrumentation
MFD Settings
The MFD control switch allows you
to set the MFD display to your pref-
erences. The rocker switch has a
MODE button (top) and a SET but-
ton (bottom). Specific instructions
are outlined on the following pages.
MODE
SET
MFD settings can be made with the
engine running or with the engine
off. If the engine is off, make sure
the stop switch is pressed down, and
turn the ignition key to the START
position briefly to activate the
MFD Control Switch
gauge. The gauge will illuminate for about 90 seconds.
Standard vs. Metric
The MFD will display either standard or metric units of measurement.
While viewing a screen that displays measurements (MPH, km/h or
temperatures), press and hold the MODE switch until the unit of mea-
surement changes (about 10 seconds).
ACE Suspension Adjustment (IQ Cruiser)
The MFD control switch also operates the M-10 ACE rear suspension
adjustment. When the blue ACE adjustment switch on the console is in
the GAUGE position, the MFD control switch functions the same as on
all other FST models. When the switch is in the ACE position, you may
use the MFD control switch to adjust the rear suspension. See page 69
for instructions.
NOTE: The engine must be running to make suspension adjustments with the
MFD control switch.
42
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FEATURES
Instrumentation
MFD Settings
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 read-
ings, 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 viewing 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.
Analog
Display
Digital
Display
Analog
Screen
Digital
Screen
Option
1
Speed
RPM
Blue “MPH”
Blue
Backlight
2
RPM
Speed
Red
“X100RPM”
Red
Backlight
43
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FEATURES
Instrumentation
MFD Digital Display Programs
Press and release the MODE button to cycle through the three MFD pro-
grams: Performance, Engine and History. Each program remains active
until you cycle to the next program. While any program is active, press
and release the SET button to cycle through the program’s screens.
Performance Program
Press and release the MODE button until the performance program
screen is active. The default display for this screen includes electrical
system voltage (unless equipped with ACE suspension adjustment), fuel
level (if equipped) and either speed or tachometer, whichever is
selected. See page 43.
Press and release the SET button to cycle through the following screens:
odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is
low) and clock (if equipped). Use the following procedures to make
changes to these screens.
Odometer Setting
The odometer records the vehicle's total
distance traveled since manufacture. The
odometer cannot be reset.
Trip Settings
Trip 1 and Trip 2 are odometers used
to check fuel mileage or to keep
track of distance traveled. Both
odometers can be reset to zero.
1. Enter the Performance Program.
2. Press and release the SET button
until the desired trip screen is
active.
3. Press and hold the SET button for two seconds to reset the trip
odometer to zero.
4. Press and release the SET button to cycle through additional
screens.
44
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FEATURES
Instrumentation
MFD Digital Display Programs
Performance Program
Trip Settings
Trip F automatically displays when the
fuel level is low if the snowmobile is
equipped with an electronic fuel gauge.
The fuel symbol and the last fuel bar on
the MFD gauge (if equipped) will blink
when the fuel level reaches 1/8 of a tank.
The Trip F odometer records distance
traveled, and the fuel symbol continues
to blink, until enough fuel is added to
raise the level above 1/4 of a tank. The
Trip F odometer will automatically reset
to zero after refueling.
45
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FEATURES
Instrumentation
MFD Digital Display Programs
Performance Program
Clock Setting (if equipped)
1. Enter the Performance Program.
2. Press and release the SET button
until the clock screen is active.
3. Press and hold the SET button for
five seconds.
4. When the hour starts flashing,
press the SET switch once to advance one hour.
NOTE: Press and hold the SET button to advance the hours quickly.
5. Press and release the MODE button to save the hour. The minutes
will begin flashing.
6. Set the minutes in the same manner.
7. When finished, press and release the MODE button to save the new
setting.
NOTE: If the MODE button is not pressed within ten seconds, the gauge will
automatically save the new entry.
46
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
Press and release the MODE button until the engine program screen is
active. The default display for this screen includes engine hours, electri-
cal system voltage level, fuel level (if equipped) and either engine cool-
ant temperature, air temperature (accessory) or altimeter (accessory).
Press and release the SET button to cycle through the following screens:
hour meter, engine temperature, air temperature (available as an acces-
sory), altimeter (available as an accessory) and turbo boost (if
equipped).
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.
Air Temperature (if equipped)
The MFD displays actual air temperature in
either standard or metric units.
1. Enter the Engine Program.
2. Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.
47
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
Altitude (if equipped)
The rider can calibrate the altimeter for current
atmospheric conditions. Altimeter accuracy
will be +/-300 ft. (91 m) after adjustment.
1. Enter the Engine Program.
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.
2. Press and release the SET button until the altimeter screen is active.
3. Press and hold the SET button for five seconds. When the digits
begin to flash, release the button.
4. Press and release the SET button once to advance 50 feet (15 m).
NOTE: Press and hold the SET button to advance quickly by 100-foot (30 m)
increments.
5. Adjust the altitude display to within 50 ft. (15 m) of current altitude.
NOTE: The gauge reads barometric pressure and allows the rider to compen-
sate 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.
6. Press and release the MODE button to set the reading at the adjusted
value.
NOTE: If the MODE button is not pressed within ten seconds, the gauge will
automatically save the new entry.
Turbo Boost (Turbo models)
Turbo boost pressure displays in
the fuel level area of the gauge.
The word BOOST will also display
when this screen is active.
48
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
Press and release the MODE button until the history program screen is
active. This screen will always display electrical system voltage level
and fuel level (if equipped).
Press and release the SET button to cycle through the Maximum Vehicle
Speed, Maximum Engine RPM and Service Interval Reminder screens.
Maximum Speed/Maximum RPM
The gauge automatically logs the maximum
speed and engine RPM even if the history
program is not active in the display.
1. Enter the History Program.
2. Press and release the SET button until
one of the two screens is active.
NOTE: The MPH and RPM values are both
reset at the same time. Reset the val-
ues before each run to obtain accurate
readings.
3. Press and hold the SET button for three
seconds to reset the recorded maximum
values for both MPH and RPM.
NOTE: Due to electrical noise, the MFD may
occasionally display MAX MPH/RPM values that are not representa-
tive of actual values.
49
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
Service Interval Reminder
The gauge logs the number of engine
hours accumulated 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 engine is started
(until the service reminder is reset.) Use
the following procedures to reset the
reminder.
To reset the reminder at the existing interval:
1. Enter the History Program.
2. Press and release the SET button until the service interval screen is
active.
3. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.
4. When the display stops flashing, release the button. The service
interval has been reset.
50
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
Service Interval Reminder
To reset the reminder at a new interval:
1. Enter the History Program.
2. Press and release the SET button until the service interval screen is
active.
3. Press and hold the SET button for five seconds, until the hours begin
to flash. 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.
5. Press and release the MODE button to save the new settings.
To disable the service interval reminder:
1. Press the SET button once after reaching 250 hours on the display.
The gauge will display "OFF".
51
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FEATURES
Instrumentation
MFD Digital Display Programs
M-10 ACE Suspension Adjustments (Cruiser)
A switch on the console
Adjustment Switch
(above the ignition switch)
allows you to adjust the
M-10 ACE suspension
with the MFD control
switch. See page 69 for
instructions.
GAUGE
ACE
MFD Battery Replacement
Models equipped with the clock feature
have a battery to power the clock. If the
clock function of the MFD isn't working
properly, replace the battery. Replace-
ment batteries are available from your
dealer.
1. Remove the plenum from the under-
side of the hood.
2. Locate the black battery compart-
ment. 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.
3. Cut the plastic cable tie from the
outside of the compartment.
4. Carefully cut the bottom of the compartment (opposite the wires) to
separate the heat-sealed seams. Squeeze the corners of the compart-
ment inward so the battery is visible.
NOTE: Note the orientation of the battery before removing it. An incorrectly
installed battery will not maintain the clock.
52
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FEATURES
Instrumentation
MFD Battery Replacement
5. Using needle-nose pliers, grasp the battery and rotate it so the lead-
ing edge of the battery is raised 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.
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 pro-
tective 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.
53
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THE PERFECT FIT
IQ Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for approximately 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 snowmobile should be methodically tested,
one change at a time, under the same conditions (trail and snow condi-
tions, vehicle speed, riding position, etc.) after each adjustment until the
best ride is achieved.
IFS Components
1. Skis
2
2. Front shocks and springs
1
3. Rod ends
3
4. A-arms
IFS Adjustment Options
• Front shock spring preload
• Optional springs
• Toe (ski alignment) (see
4
page 144)
• Camber (see your dealer)
54
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IQ Front Suspension Adjustments
Front Shock Spring Preload
The factory preload setting should be appropriate for most riders and
conditions. Please see your Polaris dealer for assistance before attempt-
ing to adjust preload.
Increasing the spring preload too much may adversely affect the han-
dling of the snowmobile and the performance of the rear suspension.
Decreasing the spring preload too much may allow the lower spring
retainer to fall off.
55
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IQ Front Suspension Adjustments
Shock Valving
The shocks can be revalved if spring preload alone isn't sufficient and
further adjustment is desired to control suspension stiffness.
WARNING
Changing shock valving 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 cau-
tion when handling high-pressure service equipment. We recommend that
this work be performed by a Polaris dealer.
Front Springs
The front spring rates can be adjusted by changing the nitrogen pressure.
The upper chamber adjusts the main spring rate. The lower chamber
adjusts preload. See your Polaris dealer for more information.
56
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Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and deliver
excellent performance for a given set of conditions. However, all sus-
pension designs and adjustments involve a compromise, or trade-off.
For example, a suspension set up for snow-cross racing would provide a
very stiff ride on the trail. A suspension set up for trail riding would bot-
tom out harshly on a snow-cross course.
Make adjustments to one area at a time so you can evaluate the change.
For further assistance, see your dealer.
Suspension Performance Tips
• Rider weight usually determines the position at which the spring pre-
load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
• In deep snow, a new rail slide will offer improved performance over a
worn slide. It can also improve top speed.
• 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 com-
ponents. Grease rear suspension pivots before adjusting the rear sus-
pension. Refer to the suspension lubrication information beginning on
page 113.
57
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IQ Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the rear suspension torsion
spring preload, measure the distance
between the ground and rear bumper.
This is measurement X.
Take the first measurement with no
rider and with the rear suspension at
full 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 measure-
ment X. This is measurement Y.
Y
To determine sag, commonly referred to as ride-in, subtract measure-
ment Y from X (sag=X-Y). If the measured sag is incorrect, adjust the
FRA position and/or rear torsion spring preload.
See
Suspension Recommended Sag Adjustment
Page
IQ Comfort
(136)
4-5 inches (10-13 cm)
Torsion Spring
Preload
59
NOTE: This is only an initial setup, and final spring preload may vary based on
rider preference and riding conditions.
NOTE: Accessory springs with a higher load rating are available for Touring
models with the IQ Comfort rear suspension, P/N 7043368 (left) and
P/N 7043369 (right). Please see your dealer for availability.
58
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IQ Rear Suspension Adjustments
Torsion Spring Preload
To adjust rear torsion spring preload, rotate the three-position cam using
the engine spark plug tool. Adjustment is easiest when the cam is
rotated from low to medium, and then to high. Rotating directly from
low to high will require significantly more effort.
Different rate torsion springs are available if a firmer ride is desired. See
your dealer for more information.
Soft
Medium
Firm
59
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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 sus-
pension coupling, these torque arms could move independently of each
other. Rear suspension coupling links the movement of the front and
rear torque arms to each other. There are two types of rear suspension
coupling.
Front To Rear Coupling and the Front Rear Scissor Stop
(FRSS)
The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of indepen-
dence between the movement of the front torque arm and the rear torque
arm.
When hitting a bump, the front torque arm starts to compress. The FRSS
links that movement to the rear torque arm, causing it to compress and
raise the rear suspension up as one, allowing the suspension to hit the
bump only once and reducing kickback.
The factory setting is usually adequate for all riders and conditions.
60
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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 indepen-
dent movement between the rear torque and the front torque arm.
Adjusting the RRSS either allows more weight to transfer to the rear for
more traction, or allows less weight to transfer to the rear, resulting in
improved cornering performance. An adjustment dot is located on the
RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop (RRSS) - Attributes
Moving the RRSS to a higher position will have the following effects on
the suspension:
• Reduced weight transfer.
• Improved chatter bump ride.
• Improved cornering performance.
• Increased load carrying capacity (2-up)
61
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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 is the
best for most trail riding conditions.
HIGH
LOW
LOW
MEDIUM
To decrease weight transfer under
acceleration (for improved corner-
ing), rotate the RRSS to a higher
position.
To increase weight transfer or ski lift
during acceleration, rotate the RRSS
to a lower position.
NOTE: Your dealer can help you with
initial setup and additional setup
instructions to help you achieve
your optimum ride. A scissor
stop tool is also available from
your dealer.
62
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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 suspen-
sion.
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 suspen-
sion, sag is controlled by two settings, the full range adjuster (FRA)
position and the rear spring preload.
63
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FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
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
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 65 and 69.
Y
X
See
Page
Suspension Recommended Sag Adjustment
M-10 136
3-4 inches (8-10 cm)
Rear Spring
Preload
66
NOTE: This is only an initial setup, and final spring preload may vary based on
rider preference and riding conditions.
64
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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 (see page 68) to determine
the desired FRA position.
2. To adjust, see page 69.
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.
65
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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
Least
Sag
Most
5135077
(standard on M-10 128)
5436109
5134923
Middle
Most
Middle
Least
5135080
(standard on M-10 136)
NOTE: Whenever ordering any of the retainers listed in the chart, always
order the retainer insert as well. The insert is not removable once
installed, so a new insert is needed when installing a new retainer.
66
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FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
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.
1. Determine if the rider
prefers comfort or con-
trol. Lean toward the #4
setting for comfort and
toward the #3 setting for
aggressive riding.
4
3
2
1
2. For full hole adjust-
ments, remove the 5/16"
nut and flat washers from
the lower attachments of
the limiter straps and
2
3
4
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.
67
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FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
Ski Pressure
4. There are also two front
arm mounting holes in the
slide rail that can adjust ski
pressure. The lower hole
increases ski pressure
Upper
Lower
while the upper hole
decreases ski pressure.
NOTE: By design, the BIASED COUPLE design of the M-10 suspension dis-
places 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
These charts are a guideline to be used for initial suspension set-ups.
Your set-up may vary based on your desired riding style.
M-10 136
Rider(s) Weight with Gear
(lbs./kg)
Suggested FRA Range
(lower number is softer)
Under 100*/45*
100-150*/45-68*
150-200*/45-90*
200-250/90-113
250-300/113-136
300-350/136-159
350+/159+
1 to 1 1/2
1 1/2 to 2
2 to 2 1/2
2 1/2 to 3
3 to 3 1/2
3 1/2 to 4
4 to 5
*You may prefer an optional rear track middle spring retainer. See page 66.
68
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FAST M-10 ACE Rear Suspension Adjustments
MFD Suspension Adjustments (Cruiser)
A switch on the console
(above the ignition switch)
Adjustment Switch
allows you to adjust the
M-10 ACE suspension
with the MFD control
switch.
GAUGE
ACE
NOTE: The engine must be
running to make
suspension adjust-
ments with the MFD
control switch.
1. Place the console rocker switch on the gauge setting.
2. Press and release the MODE
switch until the RIDE icon
appears in the voltage display
area.
Ride Setting Display
3. Place the console rocker
switch on the ACE setting.
4. Press and release the MODE
button to increase the ACE set-
ting for a firmer ride.
5. Press and release the SET button to decrease the ACE setting for a
softer ride.
NOTE: Each time the MODE or SET button is pressed, the ACE suspension
will adjust one position. The RIDE display indicates the new position
and the former position by flashing the bars between the two positions,
one bar for each level of adjustment. Press and hold the MODE or
SET button for 3 or more seconds to adjust the suspension to the fully
firm or fully soft position. The suspension is fully adjusted when no
bars flash in the RIDE display.
6. Return the console switch to the gauge setting to operate the MFD
gauge.
69
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Handlebar Adjustments
Use the RIDER SELECT feature to adjust handlebar position. See page
34. Use the following steps to adjust handlebar angle at the handlebar
block.
1. Remove the handlebar cover
to expose the handlebar and
Handlebar
Cover
the four adjuster block bolts.
2. Using a 7/16" wrench, loosen
the four nuts on the bottom of
the adjuster block (turn han-
dlebar to left or right for
access to back nuts).
Adjuster
Block
Bolts
NOTE: If necessary, pry the blocks
apart with a screwdriver.
3. Adjust the handlebar to the
desired height. Be sure han-
dlebars, 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.
Nuts
4. Torque the front bolts first, then torque the rear bolts. Torque the
bolts to 15-17 ft. lbs. (20-23 Nm).
5. Reinstall the handlebar cover.
70
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Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.
Use only Polaris parts and accessories on your Polaris snowmobile. Use
of unapproved parts and accessories may result in:
• Non-compliance with government/industry requirements
• Voiding of warranty
• Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems.
NOTE: Exhaust systems are critical safety areas that must use approved
Polaris parts. Please see your Polaris dealer for service.
71
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Traction Products
Studs
Before equipping your snowmobile 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 warran-
ties are void if track damage or failure results from improper or exces-
sive 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 73.
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 tun-
nel.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering abil-
ity 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 avail-
able. 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 the outside edge of the track.
72
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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 145.
If your snowmobile has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used.
Install the appropriate wear strip kit. See your dealer.
Wear strips are designed for a specific stud length. See your dealer's
studding chart for recommended traction accessories.
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.
73
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PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the refer-
enced pages. Look for a checkmark (n) on the referenced pages to
locate the pre-ride inspection items.
Item
See Page
Drive Belt Condition
Steering System
135
76
Parking Brake Lock/Brake Lever/Brake System
Throttle Lever
77, 78, 129
75
Throttle Safety Switch
Auxiliary Shut-Off Switch (Engine Stop Switch)
Ignition Switch
75
81, 95
81, 95
81
Taillight/Brakelight/Headlight
Coolant Level
123
Gearcase Oil Level
115
Engine Oil Level
104
Foam Oil Breather Element
Suspension Mounting Bolts
Skags (Wear Bars)
112
80
73, 145
80
Ski Saddle and Spindle Bolts
Hood Straps/Latches
76
Seat Latches
75
Rear Wheel Idler Bolts
Track Alignment/Condition
Rail Slide Condition
80, 141
79, 142
142
Oil Level (check before operating if vehicle was tipped
over)
82
74
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.
WARNING
Operating the vehicle with worn, damaged, or malfunctioning components
could result in serious injury or death. Never start the engine without check-
ing all vehicle 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 func-
tion 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 snowmobile is operated.
See page 92 for procedure.
n Seat Latches
Ensure that the seat latches are securely in place before every use of the
snowmobile.
75
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PRE-RIDE INSPECTIONS
Before Starting the Engine
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 snowmo-
bile.
n Steering System
WARNING
Ice and snow build-up may interfere with the steering of your snowmobile,
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.
76
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Brakes
Always check the following items for proper operation before starting
the engine.
Brake Lever Travel
Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2" (1.3 cm).
1/2" (1.3 cm)
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. Refer
to the brake bleeding infor-
mation on page 131.
Brake Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 130.
Check for the presence of air in the fluid system. See page 131 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.
77
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Parking Brake Lever Lock
Use the parking brake lever lock only
when you want the snowmobile to
remain stationary; for example, when
parked on an incline for a period of
five minutes or less.
1
2
3
4
1. Brake Lever
2. Parking Brake Lever Lock
3. Master Cylinder Reservoir/Cover
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze the brake lever tightly and push forward on
the lock. Hold the lock forward while releasing the brake lever.
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 parking brake light on the gauge will light up if the parking brake
lever lock is set while the engine is running. It will also be lit when the
service brake is in use. If the parking brake light does not come on when
the parking brake or service brake is in use, have it serviced by your
dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will return
to the unlocked position.
WARNING
If the parking brake lever lock is partially or entirely engaged while riding, the
brakes may overheat, resulting in brake damage. In extreme cases it could
cause a fire, which could result in serious injury or death. Always ensure that
the lever lock is completely disengaged before operating the snowmobile.
78
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Track Inspection
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 dam-
age 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.
79
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Suspension Inspection
Loose nuts and bolts can reduce your snowmobile's reliability and cause
needless repairs and down time. Before beginning any snowmobile trip,
a visual inspection will uncover potential problems. Check the follow-
ing items on a weekly basis or before any long trip.
Item
Check
Page
Suspension mounting bolts
Rear idler wheel bolts
Rear idler adjusting bolt locknuts
Torque arm bolts
Tightness
Tightness
Tightness
Tightness
Tightness
Condition
Condition
Tension
--
141
--
--
Carrier and bogie wheel bolts
Front torque arm limiter strap
Rail slide
--
--
142
140
114
--
Track
All rear suspension components
Ski runner/skag
Lubrication
Condition
Tightness
Tightness
Ski spindle bolts
--
Tie rod end nuts
--
80
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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 Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
n Mirror Adjustment
If equipped, adjust your mirrors so they can be used to their full advan-
tage.
n Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the snowmobile.
81
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PRE-RIDE INSPECTIONS
n Tip-Over Inspections
In the event of a tip-over or rollover, check the oil level before operating
the snowmobile.
CAUTION
Failure to check the oil after a tip-over can result in serious engine damage.
Always check the oil level before operating a snowmobile that has tipped
over or rolled over.
NOTE: In the event of a tip-over or rollover, the engine will stop. To restart the
engine, turn the key to the OFF position, then restart.
WARNING
Operating a snowmobile with accident damage can result in serious injury or
death. Do not operate the snowmobile if vehicle components have been
damaged in a collision or tip-over. Have the snowmobile inspected by an
authorized Polaris dealer.
82
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OPERATION
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Never start the engine or let it run in an enclosed area. Engine exhaust
fumes are poisonous and can cause loss of consciousness or death in a
short time.
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.
83
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OPERATION
Break-In Period
The break-in period for your new Polaris snowmobile is the first 500
miles (800 km) of operation. No single action on your part is as impor-
tant as following the procedures for a proper break-in. Careful treatment
of a new engine and drive components will result in more efficient per-
formance and longer life for these components.
CAUTION
Excessive heat build-up during the first 500 miles (800 km) of operation will
damage close-fitting engine parts. Do not operate at full throttle or high
speeds for extended periods during the break-in period.
Use of non-recommended oil may cause serious engine damage. Always
use the recommended oil for your Polaris snowmobile.
1. Fill the fuel tank with the recommended fuel. See page 89.
2. Check the oil level in the oil tank. See page 104. Add oil if neces-
sary to maintain at the recommended level.
3. Drive slowly at first. Vary the throttle positions. Do not operate at
sustained idle.
4. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 74.
5. During the break-in period, change both the oil and the filter at 500
miles or before seasonal storage, whichever comes first.
84
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OPERATION
Starting the Engine
CAUTION
Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never engage
the starter when the engine is running.
1. Turn the key to the ON position.
2. Pull the engine stop switch up to the RUN position.
3. Do not apply throttle when starting the engine unless extremely cold
temperatures (below -15° F/-26° C) prevent the engine from start-
ing.
NOTE: Under these conditions, attempt to start the engine without using the
throttle. If two to three attempts are unsuccessful, apply 1/8 to 1/4
throttle while cranking the engine. Ease off the throttle immediately
when the engine starts. Continue to apply just enough throttle to keep
the engine running until it idles smoothly.
4. Turn the key to START to crank the engine. Release the key to the
ON position when the engine starts.
5. Repeat the cranking procedure as needed until the engine starts.
NOTE: Always allow the engine to warm up to full operating temperature
(150° F/65° C) before shutting it down. Avoid starting and stopping the
engine with less than 5 minutes of run time when the engine is cold.
85
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OPERATION
Emergency Starting
If the battery is too weak to start the engine, and a battery charger is not
available, the engine can be started using jumper cables and a charged
battery from another vehicle. Carefully read and follow the instructions
on the following pages.
WARNING
Improperly connecting or disconnecting jumper cables can result in an explo-
sion and cause serious injury or death. When connecting jumper cables,
always connect the negative (usually black) cable last. When removing
jumper cables, always disconnect the negative (usually black) cable first.
WARNING
Loose-fitting clothing can get caught in the engine when the vehicle is run-
ning with the hood open. This can cause serious injury or death. Remove or
control all items that could catch in the engine, including scarves, gloves,
jackets and clothing straps and hooks.
NOTE: If a car or truck battery will be used to jump start the snowmobile, turn
the engine off. A running engine will put out too much electrical current
for the snowmobile battery.
NOTE: Never attempt to jump start a discharged battery that is frozen.
86
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OPERATION
Emergency Starting
1. Always wear eye protection when jump starting your vehicle.
2. Keep bystanders away from the vehicles.
3. Perform the emergency starting procedure in a well-ventilated area.
4. Position the vehicles close enough for the jumper cables to reach
easily between the batteries, but do not allow the vehicles to touch
each other.
5. Lock the parking brakes on both vehicles to prevent accidental
movement.
6. Open the hood and remove the left side panel.
7. Decide which of the jumper cables will be positive (usually red or
yellow) and which will be negative (usually black).
NOTE: Never connect a jumper cable to the fuel system or fuel lines.
8. Pull back the red plastic boot covering the positive terminal of the
weak battery. Connect one end of the positive jumper cable to the
positive terminal of the weak battery.
9. Connect the other end of the positive jumper cable to the positive
terminal of the charged battery.
NOTE: Make sure that the end of the negative cable by the weak battery is not
contacting the snowmobile battery or chassis.
10. Connect the other negative end of the jumper cable to the negative
terminal of the charged battery.
11. Connect the end of the negative jumper cable by the weak battery to
the CHASSIS of the snowmobile. There may be a small spark when
this is done, but this is normal.
NOTE: Always be sure that the jumper cables do not interfere with the belts,
pulleys or clutches on either vehicle.
87
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OPERATION
Emergency Starting
12. Make sure that the engine stop switch is in the UP position.
13. Attempt to start the vehicle.
14. If the engine does not turn over (crank over), wait 30 to 60 seconds
and attempt to start the engine again. If the engine does not start,
wait another 1 to 2 minutes and attempt to start the engine again.
15. If the engine still does not start, try adjusting the clips on the jumper
cable ends to ensure that they have a good electrical connections.
Repeat step 14.
16. If the engine still does not start, remove the jumper cables as out-
lined in step 17 and transport the snowmobile to an authorized
Polaris dealer for service.
17. Carefully remove the jumper cables in this order:
A. Remove the negative end of the jumper cable from the
snowmobile chassis.
B. Remove the negative end of the jumper cable from the
charged battery.
C. Remove the positive end of the jumper cable from the
charged battery.
D. Remove the positive end of the jumper cable from the
weak battery.
18. Reinstall the left side panel.
19. Close and secure the hood.
88
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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 perfor-
mance will be lost and fuel economy will decrease. Do not use lower
than 87 octane fuel. Do not use fuel containing more than 10% ethanol
(including E85).
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 snowmo-
bile 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 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or additives
containing methanol. Polaris also recommends the use of Carbon Clean
Plus. See page 151 for the part numbers of Polaris products.
If you use oxygenated fuel containing ethanol, additional alcohol deic-
ers or water absorbing additives should not be used.
89
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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 throt-
tle during warm-up or when the track is free-hanging. Be sure the rear sup-
port is stable.
WARNING
Use of traction products such as studs, ice growsers, etc. will increase the
possibility of track damage and/or failure. This could cause loss of control,
resulting in serious injury or death. Always inspect for track damage before
operating the snowmobile.
90
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OPERATION
Track Warm-Up
Follow these steps to ensure proper
warm-up of the engine, drive train and
track.
1. Use an appropriate stand to securely
support the rear of the snowmobile at
the rear bumper. The track should be
approximately 4" (10 cm) off the
ground.
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 revo-
lutions.
NOTE: It will take longer to warm up the track sufficiently during colder out-
door temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the snowmobile to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
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OPERATION
n Engine Stop Switch
Stop Switch
Push down on the engine stop switch to
ground out the ignition and stop the
engine quickly. Pull the switch up to the
RUN position to allow restarting.
n Throttle Safety Switch
The throttle safety switch is designed to limit engine speed to 2400
RPM whenever all pressure is removed from the throttle lever and the
throttle cable or throttle valves do not return to the normal closed posi-
tion. If the throttle lever is depressed with a throttle valve error, the Mal-
function Indicator Lamp will come on and vehicle speed will be limited
to 18 MPH (29 km/h).
See page 38 for more information about conditions that will cause vehi-
cle speed and engine speed to be limited.
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 limit engine speed to 2400 RPM when all pressure is removed from
the throttle lever during a throttle malfunction, immediately push down the
engine stop switch. Do not start the engine again until the malfunction has
been corrected by your dealer.
This four-stroke snowmobile has a self-diagnostic check of the throttle
safety switch. The switch operation is checked through the engine con-
trol unit for correct operation. If a defective switch is detected by the
self diagnostics system, the MIL will illuminate. Take your snowmobile
to an authorized Polaris dealer for diagnosis and repair if the MIL is illu-
minated.
92
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OPERATION
n 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 speed limits at 2400 RPM 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.
NOTE: Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
snowmobile to an authorized Polaris dealer for service.
Turbo Noise (Turbo models)
Under some conditions, when the throttle lever is released the boost
pressure dump valve will release pressure, and you may hear the sound
of escaping air. This is a normal occurrence on turbo-charged models.
93
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OPERATION
Electronic Reverse (PERC 4t)
Electronic reverse will activate only when the vehicle is stopped and
engine speed is below 2500 RPM. Maximum vehicle speed when oper-
ating in reverse will be approximately 12 MPH (19 km/h).
WARNING
Improper reverse operation, even at low speeds, may cause loss of control,
resulting in serious injury or death. Damage will occur to the gearcase or
transmission if shifting is attempted when the engine is operating above idle
speed.
• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.
• Look behind the snowmobile before and while backing.
• Avoid sharp turns.
• Apply throttle slowly.
CAUTION
Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never engage
the starter when the engine is running.
Engaging Reverse
1. Stop the snowmobile and
leave the engine idling.
2. Make sure the area behind
your snowmobile is clear.
3. Push the yellow reverse but-
Reverse Button
ton on the left-hand control
for one second, then release.
NOTE: A reverse light on the instrument panel will indicate that the transmis-
sion is in reverse.
4. Apply the throttle slowly to make sure the transmission is in
reverse.
NOTE: If the engine stops running, the transmission will be in forward gear
when it's restarted.
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OPERATION
Electronic Reverse (PERC 4t)
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Push the yellow reverse button for one second and release. The light
on the instrument panel will shut off.
3. Apply the throttle slowly to make sure the transmission is in for-
ward.
n Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 92 for more information about the
engine stop switch.
THROTTLE
CONDITION
SYSTEM
Ignition Switch
WHAT IT DOES
Interrupts ignition circuit
Slows jackshaft
All
All
All
Brake
Engine Stop Switch
Interrupts ignition circuit
95
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OPERATION
Daily Storage
At the end of each ride, park the snowmo-
bile 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 snowmobile.
Towing
Do not use the front bumper to pull or drag the snowmobile. The front
bumper is not designed for this type of use and may detach from the
vehicle if force is applied.
For your safety, do not attempt to use a tow hitch until you've read the
following warnings and understand the proper hitch functions.
WARNING
Objects towed with a rope have no braking power and can easily collide with
the rear of the snowmobile or other objects, resulting in serious injury or
death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a
rope. Only a stiff metal pole connecting the towed object and the tow hitch on
the snowmobile should be used. If passengers are to be towed on a tobog-
gan or sled, make sure the pole is at least four feet (1.2 meters) long to pre-
vent 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 con-
trol 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 seri-
ous damage to the engine and drive system. Always remove the drive belt
from a disabled snowmobile before towing.
96
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MAINTENANCE
Emission Control Information
Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission con-
trol information (ECI) label and a factory-installed emissions informa-
tion hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. The emission control system designation
per SAE J1930 is MFI. If your snowmobile is equipped with a check
engine light and it comes on, you must take your snowmobile to a quali-
fied dealer for diagnostic service. Specifications and adjustments for
engine tune-ups are located in the Service Manual, which is available to
your qualified service technician. Reverse (if equipped) must not be
engaged during engine tune-ups.
97
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MAINTENANCE
Emission Control Information
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty on
page 166, and read the maintenance section of your owner's manual.
You are responsible for ensuring that the specified maintenance is per-
formed, including the emission-related maintenance outlined in these
sections of the manual.
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 speci-
fied maintenance for the fuel filter is recommended additional emission-
related maintenance. Polaris recommends that you contact an authorized
Polaris dealer to perform any service that may be necessary.
98
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MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out-
lined in this manual. Record maintenance and service in the Mainte-
nance Log beginning on page 168.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1500 miles (2400 km). These inspections should be per-
formed by a qualified service technician. For continued optimum perfor-
mance and component life, continue maintenance checks at 1500 mile
(2400 km) intervals.
All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the regis-
tered owner. If, during the course of the warranty period, part failures
occur as a result of owner neglect in performing recommended regular
maintenance, the cost of repairs are the responsibility of the owner.
Personal safety is critical when attempting to service or make adjust-
ments to your snowmobile. If you're not familiar with safe service or
adjustment procedures and the use of tools, or if you don't feel comfort-
able performing these tasks yourself, contact an authorized Polaris
dealer for service.
NOTE: Polaris does not recommend tipping the snowmobile onto it's side for
service. Any time the snowmobile is tipped onto it's left side, always
check the oil level and clean the foam oil breather element. See page
112.
CAUTION
Hot components can cause damage to plastic. Always make sure the
exhaust system and engine have cooled if you must tip the snowmobile on its
side for service or inspection.
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MAINTENANCE
Periodic Maintenance Interval Table
O = Perform Service
X = Replace
INITIALLY
Miles (km)
150
(240)
500
(800)
1500
(2400)
Item
Pg
Instructions
(see referenced pages)
Engine Stop Switch
Ignition Switch
81 Test for proper operation.
O
O
O
O
O
O
O
Do not operate if switches
81
fail, see your dealer for ser-
Throttle Safety Switch 92 vice.
Taillight
81 Test for proper operation,
replace bulbs as needed
Brakelight
81
81
Headlight
Skags (Wear Bars)
145 Inspect for wear or damage,
replace when worn
Fluid Leaks
--
Inspect for fluid leaks
O
O
Parking Brake
78 Test for proper engagement
and release, see your
dealer for service
Brake Lever
77 Check lever travel and lever
“feel”
O
Coolant
123 Inspect level, add as
O
O
O
O
O
needed
CHANGE EVERY 2 YEARS
Brake fluid
Hood Latches
Seat Latches
Rail Slide
130
76 Secure properly, replace if
damaged
75
142 Inspect for wear or damage,
replace when worn
Foam Oil Breather
Element
112 Check pre-ride, clean or
replace with each oil
O
O
O
O
change. Clean after tipping
3 times onto left side.
WEEKLY / BEFORE LONG TRIPS
WEEKLY / BEFORE LONG TRIPS
Front and Rear Sus-
pension and Steering
Fasteners
80 Inspect for missing or loose
bolts and fasteners, tighten
or replace as needed
Front Limiter Strap
--
Inspect for wear, damage
and missing or loose fasten-
ers, replace as needed
Oil Lines
--
Inspect, replace if worn or
damaged
O
O
O
O
O
O
O
O
Alternator Belt
120 Check tension and condi-
tion, replace if worn or dam-
aged
Throttle Lever
75 Verify smooth and proper
93
O
O
O
O
O
O
O
O
operation
Track Alignment
142 Verify alignment, adjust as
needed
100
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MAINTENANCE
Periodic Maintenance Interval Table
O = Perform Service
X = Replace
INITIALLY
Miles (km)
150
(240)
500
(800)
1500
(2400)
Item
Pg
--
Instructions
(see referenced pages)
Coolant Hoses
Inspect, replace if worn or
damaged
O
O
O
Heat Exchangers
Fuel Lines
--
Inspect, replace if damaged
O
O
O
O
O
O
119 Inspect, replace if worn or
damaged
Battery
146 Clean terminals, test volt-
age
O
O
O
O
O
O
O
O
Track Tension
Handlebars
Drive Chain
140 Verify tension, adjust as
needed
--
Verify alignment, adjust as
needed
O
EVERY
EVERY
128 Verify tension, adjust as
needed
Rear Track Shock
(M-10)
--
Inspect covers and caps for
wear or damage, replace as
needed
EVERY
1000
Gearcase Oil
Rear Suspension
Bearings
115 Check at 500 mi. (800 km),
change every 1000 mi.
(1600 km)
O
O
O
(1600)
114 Lubricate pivot shafts (more
often in wet snow condi-
tions)
O
O
113 Lubricate drive shaft and
jackshaft bearings
149
Throttle Cable
Clutches
113 Lubricate
O
O
O
O
134 Verify offset alignment,
inspect for wear, residue,
loose bushings, see your
dealer for all service
Drive Belt
135 Check tension and condi-
tion, replace if worn or dam-
aged
O
O
Air Filter
120 Inspect for oil and dirt,
replace as needed
O
X
O
X
Oil Change
108 Replace oil and clean the
foam oil breather element
112
101
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MAINTENANCE
Periodic Maintenance Interval Table
O = Perform Service
X = Replace
INITIALLY
Miles (km)
150
(240)
500
(800)
1500
(2400)
Item
Engine Mounts
Spark Plugs
Pg
Instructions
(see referenced pages)
--
Inspect, replace if worn or
damaged
O
O
O
O
O
O
117 Inspect condition/gap,
replace as needed
Exhaust System
121 Check muffler and pipe con-
dition, replace damaged or
missing components, clean
plastic surfaces
Hoses
--
Inspect for wear, damage
and proper routing, replace
as needed
O
O
Brake Pads/Disc
Fuel Vent Lines
Ski Toe
129 Inspect, replace if worn or
damaged
O
O
O
O
O
O
O
O
119 Inspect, replace if worn or
damaged
144 Verify alignment, see your
dealer for adjustments
Cooling Fins/Shroud
Valve Lash
--
--
Inspect and clean
1500 (2400)
INITIALLY
See your dealer
FS Specifications
Intake: 0.08 - 0.15 mm
EVERY
10,000 (16,000)
THEREAFTER
Exhaust: 0.15 - 0.20 mm
FST/Cruiser Specifications
Intake: 0.08 - 0.15 mm
Exhaust: 0.18 - 0.23 mm
EVERY
2000
Cooling System
Fuel Filter
125 Bleed the cooling system,
inspect for leaks and proper
circulation
(3200)
EVERY
2000
(3200)
119 Inspect, replace as needed
EVERY
2000
(3200)
Rear Suspension
Shock Oil
--
See your dealer
(IQ/SwitchBack/M-10)
102
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MAINTENANCE
Engine Oil
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Table beginning on page 100. Always change the
oil filter whenever changing oil. See page 151 for the part numbers of
Polaris products.
Performance Synthetic 4-Stroke (PS-4) Oil
Polaris recommends the use of Performance Synthetic 4-Stroke oil (PS-
4 or PS-4 Plus) for this engine. PS-4 has been specially formulated for
use in Polaris 4-cycle snowmobile engines. It's a fully synthetic, high
performance, multi-viscosity oil designed to provide the ultimate in
lubrication performance and protection.
Oil may need to be changed more frequently if Polaris PS-4 oil is not
used. Follow the manufacturer's recommendations for ambient tempera-
ture operation.
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine
damage. Always use the recommended oil. Never substitute or mix oil
brands.
103
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MAINTENANCE
Engine Oil
n Oil Level Check
NOTE: Read the entire oil check procedure before checking the oil level.
The oil level will rise as engine temperature increases. The oil level will
be lower when the engine is cold. To obtain a proper oil level reading,
the snowmobile must be on a level surface, and the engine coolant tem-
perature must be between 145 and 160 degrees F. (63-71 degrees C).
NOTE: Always check the oil level before operating a snowmobile that has
tipped over.
CAUTION
Severe engine damage may occur if procedures for checking the oil level are
not followed precisely. Always check the oil with the snowmobile positioned
on a level surface. Always check the oil level when the coolant temperature is
within the specified range.
104
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MAINTENANCE
Engine Oil
n Oil Level Check
NOTE: The oil level in the oil bottle may drain below the level of the dipstick if
the engine has not run for more than a week. If you're not sure if there
is oil in the system, you must first check to make sure oil is in the sys-
tem before checking the oil level. Perform the “Oil in System Check”
procedure on page 107 before performing the oil level check.
1. Position the vehicle on a level surface.
2. If the engine is cold, start the engine and allow it to idle until the
engine coolant temperature reaches the specified range. Proceed to
step 4.
3. If the engine has been running, stop the engine and verify that cool-
ant temperature is within the specified range for performing the oil
check. Allow the engine to cool if necessary. When the coolant is
within the specified range, restart the engine and allow it to idle for
no more than 20 seconds to circulate the oil back into the tank.
4. Turn the engine off.
NOTE: Check the oil level within three
minutes, before the coolant tem-
Dipstick
perature (and oil level) begin to
drop.
5. Remove the dipstick from the oil
tank.
6. Clean the dipstick with a clean
shop towel and reinstall it, screw-
ing it in completely.
7. Remove the dipstick and view the
oil level.
NOTE: The oil level reading will be accurate for only one to three minutes after
turning off the engine. If the oil check isn't completed within three min-
utes, reinstall the dipstick. Restart the engine and allow it to idle for no
more than 20 seconds to circulate the oil back into the tank.
105
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MAINTENANCE
Engine Oil
n Oil Level Check
Fill mark for oil changes
(at specified coolant temperature)
8. Maintain the oil level in
the safe operating range,
between the upper and
lower marks on the dip-
stick. If the level is low,
add the recommended oil
Safe operating range
in small increments, about 2 ounces (60 ml), and recheck the level.
NOTE: If the level is low, or when changing the oil, add only enough oil to
bring the level to the bottom of the safe operating range on the dip-
stick.
9. If the level is high, remove 2 ounces (60 ml) and recheck the level.
CAUTION
Do not overfill the oil tank. Engine damage may occur. Always add oil in small
increments and recheck the level to avoid overfilling.
10. Recheck the oil level if oil was added or removed, making sure the
coolant temperature is within the specified range. If necessary, con-
tinue adding or removing oil until the level is in the safe operating
range.
106
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MAINTENANCE
Engine Oil
Oil in System Check
1. Position the vehicle on a level surface. Start the engine and allow it
to idle 3-5 seconds (no more than 5 seconds). Turn the engine off.
2. Remove the dipstick. Clean the dipstick with a clean shop towel and
reinstall it, screwing it in completely. Remove the dipstick and ver-
ify that oil is present anywhere on the dipstick.
3. If oil is present, continue with the oil level check procedure begin-
ning on page 104.
4. If oil is not present, add 1/2 quart (.47 l) of the recommended oil.
Reinstall the dipstick, start the engine for no more than 5 seconds,
stop the engine, and recheck for the presence of oil.
5. If oil is present, continue with the oil level check procedure begin-
ning on page 104.
6. If oil is not present, add another 1/2 quart (.47 l) of oil. Reinstall the
dipstick, start the engine for no more than 5 seconds, stop the
engine, and recheck for the presence of oil.
7. If no oil is present on the dipstick, check the oil system for leaks and
proper operation or see your Polaris dealer.
107
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MAINTENANCE
Engine Oil
Oil Change
Always change the oil at the intervals outlined in the Periodic Mainte-
nance Table beginning on page 100. Clean the foam oil breather element
with each engine oil change. See page 112.
Always use the recommended oil. See page 104, or see your Polaris
dealer about oil change kits, which contain a new filter and the recom-
mended oil.
NOTE: A special jumper harness is required for changing the oil on this vehi-
cle. Please see your Polaris dealer to purchase the harness, which will
allow you to use the ignition key to turn over the engine without start-
ing it. You may also need an assistant to help with the oil change.
1. Position the vehicle on a level surface.
2. Make sure the engine coolant temperature is between 145 and 160
degrees F. (63-71 degrees C). If necessary, start the engine and
allow it to idle until the coolant temperature is within the specified
range.
3. Turn the engine off.
CAUTION
Hot oil and a hot exhaust system and engine can cause serious burns. Do
not allow hot oil or hot components to contact skin.
4. Open the hood and remove the left side panel.
NOTE: Clamp orientation is critical to the proper operation of the system. Be
aware of clamp placement and orientation when removing hose
clamps. Always reinstall hose clamps in the same location and posi-
tion.
108
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MAINTENANCE
Engine Oil
Oil Change
5. Remove the oil return hose from the oil tank. Have an assistant
place the end of the hose into a drain pan.
6. Disconnect the 2-pin WHITE/RED and GREEN/WHITE starter
motor solenoid control switch harness connector located near the
battery.
7. Rotate the plug 90 degrees and reinstall it with the WHITE/RED
wire connected.
8. Insert the male pin of the jumper harness into the starter solenoid's
female port.
9. Open the handlebar cover. Locate the 3-pin connector with the
BROWN and RED/WHITE wires. Plug this connector into the 3-
pin connector of the jumper harness.
10. Open the fuse box and remove the 20A EFI fuse from the fuse
block.
11. Reinstall the left side panel.
12. Have an assistant use the ignition key to turn over the engine. Crank
the engine for 15 seconds.
13. Wait 30 seconds to allow the starter motor to cool down.
14. Repeat steps 12 and 13 four more times for a total of five cycles.
15. Reconnect the oil return line to the oil tank. Make sure the hose and
clamp are properly seated. Make sure the clamp is in the correct ori-
entation. Refer to the NOTE following step 4.
16. To prevent oil spillage, wait 3 to 5 minutes to allow any oil in the oil
filter cap to drain out before removing it. While waiting, remove the
foam oil breather element from the airbox. See page 112.
17. Inspect the foam element. Clean it with soap and water and let it dry.
Reinstall it, or install a new element if the existing element is dam-
aged or degraded and unable to absorb liquid.
109
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MAINTENANCE
Engine Oil
Oil Change
18. Remove the oil filter cap, then remove the oil filter. Inspect the o-
ring and replace it if it's worn or damaged.
19. Install a new filter, then reinstall the cap. Tighten the cap to 18.5 ft.
lbs. (25 Nm).
20. Remove the jumper from the starter motor wiring harness. Recon-
nect the solenoid and the originally-installed harness. Reinstall the
20A EFI Fuse.
21. Remove the dipstick from the oil tank. Add 2 quarts (1.9 liters) of
the recommended oil. Reinstall the dipstick.
22. Start the engine and allow it to idle for 3-5 minutes. Make sure the
engine coolant temperature is between 145 and 160 degrees F. (63-
71 degrees C).
23. Stop the engine.
24. Remove the dipstick from the oil tank. Clean the dipstick with a
clean shop towel and reinstall it, screwing it in completely.
25. Remove the dipstick and view the oil level.
Fill mark for oil changes
(at specified coolant temperature)
Safe operating range
110
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MAINTENANCE
Engine Oil
Oil Change
26. Add additional oil to bring the level slightly above the lower mark
(in the safe operating range) on the dipstick. See the chart for
approximate amounts to add at this step. DO NOT OVERFILL.
OIL TO ADD AT STEP 26
MODEL
Ounces
4 to 16
24 to 32
Milliliters
118 to 473
710 to 496
FS
All FST
NOTE: Check the oil level often during the fill procedure to avoid overfilling. If
the filling and checking procedure is not completed within three min-
utes, reinstall the dipstick. Restart the engine and allow it to idle for no
more than 20 seconds to circulate the oil back into the tank. Continue
adding and checking the oil until the level is slightly above the lower
mark (in the safe operating range) on the dipstick. Do not overfill.
27. Reinstall the dipstick.
111
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MAINTENANCE
n Foam Oil Breather Element
The foam oil breather element absorbs small amounts of liquid to pro-
tect sensors within the intake system from damage due to oil ingestion.
Check the element before each ride. Clean or replace the breather ele-
ment at each engine oil change. Clean the element if the snowmobile has
been tipped on its left side three times, either during service or while
riding, as oil may leak into the element.
CAUTION
Operating the snowmobile with a clogged foam oil breather element can
result in severe engine damage. Always clean or replace the element as rec-
ommended.
The foam oil breather element is located
inside the airbox.
Element (FS)
1. Open the hood.
2. Release the airbox cover retaining
clips and remove the cover.
3. Remove the foam breather element.
4. Wash the foam element in soapy
water, then rinse thoroughly and let
dry.
NOTE: If soap and water are not readily
Element (All FST)
available, remove as much liquid
as possible by pressing the foam
element in paper towels or a simi-
lar absorbent material.
5. Reinstall the dry foam element, or
install a new foam element.
NOTE: Always replace a foam element
that is brittle, cracked, crumbling
or otherwise damaged. For best
performance, routinely replace the
foam element with every other
engine oil change.
6. Reinstall the airbox cover. Secure all retaining clips.
112
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MAINTENANCE
Lubrication
Driveshaft Bearing
Fitting
Inject grease into the fitting on the speed-
ometer 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.
Front Suspension
The front suspension and steering components do not require lubrica-
tion.
113
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MAINTENANCE
Lubrication
Rear Suspension
Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 100 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).
Lack of lubrication will adversely affect your ride and the life of the sus-
pension. For more information about suspension lubrication and adjust-
ments, see your Polaris dealer.
M-10 136 ACE Rear Suspension
+
+
+
+
IQ Comfort Rear Suspension
+
+
+
+
114
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MAINTENANCE
Gearcase Oil
n Gearcase Oil Check
Check and change the gearcase oil at
the intervals outlined in the Periodic
Maintenance Table beginning on page
100.
Polaris recommends the use of Polaris
Synthetic Chaincase Lube. See page
151 for the part numbers of Polaris
products.
Dipstick
The dipstick is located on the lower
front side of the gearcase. Maintain
the oil level in the safe operating
range, between the upper and lower
marks on the dipstick.
1. Position the vehicle on a level
surface.
2. Remove the dipstick and wipe it
dry with a clean cloth. Reinstall
the dipstick.
SAFE Range
3. Remove the dipstick and view the oil level.
4. Add the recommended oil as needed. Do not overfill.
5. Reinstall the dipstick.
115
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MAINTENANCE
Gearcase Oil
Gearcase Oil Change
The drain plug is located on the bottom
of the gearcase.
NOTE: Polaris does not recommend tip-
ping the snowmobile onto it's side
for service. Any time the snowmo-
bile is tipped onto it's left side,
always check the oil level and
clean the foam oil breather ele-
ment. See page 112.
1. Position the vehicle on a level sur-
face.
2. Remove the drain plug and drain the
oil into a drain pan. Allow the oil to
drain completely
NOTE: The sealing surfaces on the drain
plug and the gearcase should be
clean and free of burrs, nicks or
scratches.
Drain Plug
3. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
4. Remove the dipstick.
5. Add 9 oz. (266 ml) of the recommended oil. Do not overfill.
6. Reinstall the dipstick, making sure it is seated properly.
116
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MAINTENANCE
Spark Plugs
A new engine can cause temporary spark plug fouling due to the preser-
vative added during the assembly process. Avoid prolonged idle speeds,
which cause plug fouling and carbonization.
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.
• Use recommended spark plugs with the proper gap.
• Use only resistor-type spark plugs.
• Torque spark plugs to 18-20 ft. lbs. (24-27 Nm).
Check the spark plug firing end condition after the engine has been
warmed up and the vehicle has been driven at higher speeds. If a plug is
fouled, replace the plug with a new plug.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
117
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MAINTENANCE
Spark Plugs
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi-
cates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil or
rich fuel mixture.
118
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MAINTENANCE
Intake Filters
+
The intake foam filter limits snow
ingestion into the intake system.
When operating in loose powder
snow, check the top of the foam
filter periodically to remove any
accumulation of snow.
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 Filter
See your Polaris dealer for replacement of the fuel filter at the intervals
outlined in the Periodic Maintenance Table beginning on page 100.
Fuel Lines
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal dete-
rioration from weather and fuel compounds may occur. Replace worn or
damaged fuel lines promptly.
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.
119
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MAINTENANCE
n Alternator Belt Inspection
Inspect the alternator belt condition and tension before each ride.
1. Stop the engine.
2. Open the hood.
3. Inspect the belt for wear,
cracks or other damage. If the
belt is worn or damaged,
install a new belt.
4. Grasp the alternator belt and
attempt to twist it.
5. If the belt rotates 1/4 turn (90 degrees) or more (as shown), tighten
the belt or install a new belt.
Air Filter (Turbo)
Inspect the air filter for oil and dirt accumulation at the intervals out-
lined in the Periodic Maintenance Table beginning on page 100.
1. Open the airbox.
2. Remove the air filter.
3. Shake or pat the filter to clean it, or install a new filter. Do not
attempt to clean the filter with liquids.
Foam Oil Breather Filter
Clean or replace the breather element at each engine oil change. See
page 112. Clean the element if the snowmobile has been tipped on its
left side three times.
120
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MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at the intervals outlined in
the Periodic Maintenance Table beginning on page 100.
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.
1. Allow the engine and exhaust system to cool completely.
2. Open the hood.
3. Inspect the muffler and pipes for cracks or damage. Check for weak
or missing retaining springs or damper/support grommets.
4. Replace any damaged or missing components.
5. Clean the plastic surfaces next to the muffler with aerosol Carbure-
tor and Throttle Body Cleaner.
NOTE: See page 151 for the part numbers of Polaris products.
6. Close the hood.
121
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MAINTENANCE
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 151 for the part numbers of Polaris prod-
ucts.
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.
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 remove
the pressure cap when the engine is warm or hot.
122
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MAINTENANCE
Cooling System
n Coolant Level
The engine coolant level is controlled
by the recovery system. The recovery
system components are:
“COLD FILL”
Mark
• Coolant bottle or overflow tank
• Filler neck
• Pressure cap
• Connecting hoses
Always maintain the coolant level at
the “COLD FILL” mark on the cool-
ant tank (when the engine is cold).
CAUTION
Operating the snowmobile with insufficient coolant will result in overheating
and serious engine damage. Always maintain the coolant level as recom-
mended.
123
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MAINTENANCE
Cooling System
Coolant High Temperature Indicator Light
The high temperature indicator light will illuminate when engine cool-
ant temperature becomes too hot for safe continued operation of the
engine. Stop the snowmobile and allow the engine to cool. Place snow
on the coolers to help cool the engine. If coolant is low in the coolant
overflow bottle, add coolant to the coolant bottle. Do not open the radia-
tor pressure cap.
WARNING
Steam and hot liquids will cause serious burns to your skin. Never remove
the pressure cap when the engine is warm or hot, or if any part of the cooling
system is warm or hot.
CAUTION
Operating the snowmobile when the high temperature indicator light is illumi-
nated can result in serious engine damage. Always stop the snowmobile and
cool the engine when the high temperature indicator light illuminates.
Drive in adequate snow to prevent overheating. If you must drive your
snowmobile after the high temperature indicator light has illuminated,
drive in deep snow. Drive slowly and stop frequently to allow the engine
to cool down. Engine performance will be reduced if you continue oper-
ating when the high temperature light is illuminated.
124
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MAINTENANCE
Cooling System
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 mix-
ture of antifreeze and distilled water should be added. Have your Polaris
dealer perform this service.
Bleeding the Cooling System
Bleed the cooling system at the intervals outlined in the Periodic Main-
tenance Table beginning on page 100. In addition, bleed the cooling sys-
tem any time one or more of the following conditions exist.
• A component of the cooling system has been serviced or replaced
(including coolers, radiator, engine, coolant lines and oil cooler)
• A cooling system failure occurs, resulting in coolant loss
• A coolant line has been disconnected for any reason
• A coolant leak occurs
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.
1. Read the entire coolant bleed procedure before beginning. After
beginning the bleed procedure, do not stop the engine until reaching
step 14.
2. Move the snowmobile into a well-ventilated area. Allow the engine
to cool completely.
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.
125
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MAINTENANCE
Cooling System
Bleeding the Cooling System
3. Open the hood.
Cap
4. Remove the coolant pressure
cap carefully.
5. Slowly pour coolant into the
filler neck until the coolant
level reaches the bleed return
hole on the inside of the filler
neck. Leave the pressure cap
off.
Filler
Neck
Return
Hole
6. With the cap off, start the
engine and allow it to idle.
7. With the engine idling,
observe the coolant level in
the filler neck. Make sure that
the coolant level in the filler
neck is always visible. When
the level falls, add coolant. A
rising level is acceptable.
NOTE: During bleeding, air pockets will bubble to the surface. Add coolant
after these air pockets have surfaced, making sure that the coolant
level remains visible in the filler neck.
8. With the engine idling, and while making sure that the level in the
filler neck remains visible, observe the bleed return. If the system is
self-bleeding properly, coolant will be pumped out of this hole.
NOTE: Coolant flow may be erratic (spitting, misting) for the first few minutes
of bleeding, but as long as the procedure is followed and coolant is
visible in the filler neck, the system should bleed properly.
126
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MAINTENANCE
Cooling System
Bleeding the Cooling System
9. While observing the bleed return and making sure the coolant level
is visible in the filler neck, observe the engine temperature in the
digital display. The temperature should rise steadily, indicating that
the system is bleeding properly.
10. If the temperature does not rise after approximately one (1) minute,
repeat steps 8 and 9. Make sure steps 8 and 9 are followed precisely
during the entire bleed procedure.
11. Reinstall the coolant pressure cap when engine temperature reaches
120° (48° C). Do not stop the engine at this step.
NOTE: If the engine is stopped before the cap is installed, a large amount of
coolant will flow out of the filler neck and the entire bleed procedure
will have to be performed again.
12. While the engine temperature is rising, allow the engine to idle until
the temperature reaches approximately 220° F (104° C). Do not stop
the engine at this step.
13. Feel the coolers at the rear of the snowmobile (rear cooler, de-icers,
grippers, as equipped). These components should be warm to the
touch, indicating the thermostat is open and the entire cooling sys-
tem is bleeding. If coolant is still flowing from the bleed return and
there is coolant in the filler neck, the system has been bled properly.
14. Stop the engine. Allow it to cool completely.
15. Restart the engine and allow it to idle until the temperature reaches
120° F (49° C). Stop the engine.
16. Keeping your face and other exposed skin clear of the bleed screw
on the PTO side of the head, loosen the screw about 1/4 turn. You
should hear hot air escape. Tighten the screw immediately when
coolant begins to escape. Torque the screw to 9 ft. lbs. (12 Nm).
17. Remove the coolant overflow tank cap. Add coolant to the “COLD
FILL” mark on the tank. Reinstall the cap.
127
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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.
Adjuster
Bolt
2. Loosen the adjuster bolt jam
nut.
Jam
Nut
3. Finger tighten the adjuster
bolt 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 18-23
ft. lbs. (24-31 Nm).
5. Release the brake lever lock.
128
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MAINTENANCE
Brakes
n Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 77.
Brake pads must be replaced when the brake pad material becomes thin-
ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail-
able for replacing brake pads. See your dealer.
WARNING
Brake failure during operation can result in serious injury or death. Properly
functioning brakes are vital to your safety. Be sure the brake pads do not
drag on the disc and that brake lever travel is not excessive.
Always replace brake pads when the brake pad material becomes thinner
than the backing plate, approximately 1/16" (1.5mm).
Brake Components
• Brake Disc
• Bleed Screw
• Brake Line
• Brake Caliper
Bleed Screw
Brake Disc
Brake Line
Brake
Caliper
• Brake Pad Material -
Replace when thickness is
less than 1/16" (1.5 mm).
Brake Pad
Material
Excessive Lever Travel
Hydraulic brakes are self-
adjusting, but if excessive
brake pad clearance develops
bring the snowmobile to an
authorized Polaris dealer for
inspection and adjustment.
129
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MAINTENANCE
Brakes
n 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 rap-
idly absorbs moisture from the air. The moisture causes the boiling tempera-
ture 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
Sight Glass
years with Polaris DOT 4 high tem-
perature brake fluid. See page 151 for
the part numbers of Polaris products.
The brake fluid level can be seen
through the fluid level indicator (a
plastic sight glass) in the master cyl-
inder reservoir. If the fluid is suffi-
cient, the sight glass will be black. If
the sight glass is any color other than
black, add brake fluid.
130
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MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING
Operating the vehicle with a spongy brake lever can result in loss of brakes,
which could cause an accident and lead to serious injury or death. Never
operate the vehicle with a spongy-feeling brake lever.
During the bleeding procedure, keep the brake handle as level as possi-
ble. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.
1. Remove 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 open-
ing. 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 130.
8. Reinstall the gasket and cover.
131
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MAINTENANCE
Lights
Removing Halogen Bulbs
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 fin-
gers do touch the bulb, clean it with an alcohol-moistened towel.
1. Remove the plenum cov-
ering from the headlight
assembly.
Bulb
Spring
2. Lift the rubber boot to
expose the bulb.
3. Push down on the spring
to release it from the
housing.
Harness
4. With the wire harness
attached to the bulb,
withdraw the bulb from
the housing.
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. Adjust headlight aim. See page 31.
Replacing Taillight Bulbs
1. Remove the screws securing the taillight lens.
2. Push the bulb in and twist counterclockwise and replace the bulb.
3. Replace the taillight lens.
132
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MAINTENANCE
Electrical System
RELAY LABEL
FUSE LABEL
ITEM POWERED
START SOLENOID
RELAY
Ground side of start solenoid
SPARE 20A
None
ACCESSORY
EMERGENCY
SPARE 30A
Accessory plugs
CHASSIS
RELAY
High beams
Low beams
Handwarmers
Thumbwarmer
Tail lamp
CHASSIS
30A
Brake lamp
Alternator coils
Exhaust sensor
Gauge
EX. SENSOR
GAUGE 20A
REVERSE SHIFT
Reverse shift
Accessory projector beam relay
Diagnostic plug
Ignition relay power
Cam phase sensor
ECU hold-on power
Reverse limit switch
Forward limit switch
Start relay coil
Chassis relay coil
Ignition relay coil
Fuel pump relay coil
Fan relay coil
IGNITION 20A
EFI
RELAY
EFI
20A
Fuel pump relay power
PTO injector
MAG injector
Wastegate
IGNITION RELAY
PTO ignition coil
MAG ignition coil
Fuel pump
FUEL PUMP RELAY
FAN RELAY
CAC fan
133
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MAINTENANCE
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.
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
snowmobile 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.
Clutch Alignment Offset
Clutch alignment offset is important for maintaining optimum perfor-
mance.Please see your Polaris dealer if you experience a decrease in
performance.
Clutch Center Distance
See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.
134
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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. See Drive Belt Troubleshooting on page
158.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.
n Drive Belt Deflection
Measure belt deflection with both
clutches at rest and in their full
neutral position.
Straight
Edge
Measure
A
Place a straight edge on the belt
and apply downward pressure
while measuring at point A. 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.
135
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MAINTENANCE
Clutch System
Drive Belt Removal
CAUTION
Do not attempt to remove the drive belt after operating in reverse. The snow-
mobile must be stopped after forward motion to prevent damage to compo-
nents during belt removal.
1. Stop the engine after operating in a forward motion.
NOTE: For easier accessibility, make sure the clutch tool access hole is visible
between the 11:00 and 2:00 positions of the clutch sheave.
2. Turn the ignition key off.
Access Hole
Wait for the engine to come
to a complete stop.
3. Lock the parking brake.
4. Open the hood.
11:00
2:00
5. Remove the left side panel.
6. Install an L-wrench into the
open threaded access hole in
the outer sheave of the
clutch.
7. Turn the wrench clockwise
until the sheaves open far
enough to remove the belt.
136
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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.
4. Reinstall the side panel.
5. Close and secure the hood.
137
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MAINTENANCE
Track Replacement
When replacing the track, always install a track having the lug size rec-
ommended for your model. See your Polaris dealer.
CAUTION
Installing tracks with larger lugs on machines equipped with coolers will result
in damage to the cooler or tunnel. Always install a track having the lug size
recommended for your model.
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 sup-
port 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.
Bend the track to check for break-
age.
4. Replace the track if any rod dam-
age is found.
Rods
138
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MAINTENANCE
Track Lubrication
WARNING
Operating with insufficient lubrication between the rail slide and track guide
clips can cause track failure, loss of vehicle control and loss of braking ability,
which can result in serious injury or death.
Avoid operating for extended periods on ice and other surfaces that have lit-
tle or no snow for lubrication.
The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new rail slide can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.
NOTE: Track damage or failure caused by operation on ice or under other
poor lubrication conditions will void the track warranty.
CAUTION
High speed use on hard-packed surfaces is not recommended for models
equipped with a deep lug track. Track lug damage may occur. Keep high
speed use to a minimum, including frequent slow-speed intervals for track
cooling.
139
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MAINTENANCE
Track Tension
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 run-
ning.
Track adjustment is critical for proper handling. Always maintain cor-
rect tension and alignment.
TRACK TENSION DATA CHART
Measurement
Suspension
Slack Measurement
Weight
Location
IQ Comfort
M-10 136
7/8"-1 1/8" (2.2-2.9 cm)
7/8"-1 1/8" (2.2-2.9 cm)
10 lbs.
(4.54 kg)
16" (40 cm)
ahead of rear
idler shaft
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 snowmo-
bile 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.
S
10 lbs.
(4.54 kg)
NOTE: Measure at the point where
16" (40 cm)
the weight is hanging.
140
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MAINTENANCE
Track Tension
4. Check for specified slack between the wear surface of the track clip
and the plastic rail slide.
Idler Shaft
Bolt
Adjusting
Screw
Lock
Nut
If the track needs adjustment:
5. Loosen the rear idler shaft bolt.
6. Loosen the lock nuts.
7. Tighten or loosen the track adjusting screws as necessary 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 snowmobile is new.
9. Start the engine 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 142) and adjust as necessary.
11. Tighten the lock nuts.
12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).
141
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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
snowmobile 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 com-
plete revolutions. Stop the engine
and let the track come to a stop
(do not apply brakes).
Rails
3. Inspect track alignment by looking through the track window to
make sure the rails are evenly spaced on each side. If the track runs
to the left, loosen left locknut and tighten the left adjusting bolt. If
the track runs to the right, loosen right locknut and tighten the right
adjusting bolt.
4. After adjustments are complete, tighten locknuts and torque idler
shaft bolts to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
n Rail Slide Wear
For ease of inspection, all
Polaris rail slides have a
wear limit indicator groove
to indicate the minimum per-
missible slide thickness.
Minimum
Thickness
Replace the rail slides if they
are worn to the top of the
groove at any point along
their length. Failure to do so
may result in permanent
Replace when
worn to top of
groove
damage to the track or rails.
142
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MAINTENANCE
Steering System
Steering Inspection and Adjustment
Check all steering system fasteners weekly and before a long ride.
Tighten any loose fasteners.
+
+
+
+
+
143
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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 align-
ment 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" (3-6 mm) 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 in.
(25.4 cm)
10 in.
(25.4 cm)
Y
144
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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 steer-
ing characteristics. Skags must be replaced when worn to half their orig-
inal diameter.
NOTE: Carbide skags must be replaced if any abnormal wear or chipping is
found.
Skag Replacement
NOTE: Some models are equipped with single skags. Some models are
equipped with dual skags.
1. Raise and support the front of
the snowmobile so the skis are
approximately 6" (15 cm) from
the ground.
2. Remove the attaching nuts and
pry the skag 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.
Skag
145
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MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result in an explo-
sion and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery,
always connect the negative (black) cable last.
Battery Removal
1. Remove the left side panel.
2. Disconnect the battery hold-down strap.
3. Disconnect the black (negative) battery cable first.
4. Disconnect the red (positive) battery cable last.
5. Lift the battery out of the vehicle.
Battery Installation
When installing a new battery, make sure it's fully charged prior to its
initial use. Using a new battery that has not been fully charged can dam-
age the battery and result in a shorter life. It can also hinder vehicle per-
formance. Follow the battery charging instructions on page 148 before
installing the battery.
1. Ensure that the battery is fully charged.
2. Set the battery in the battery holder.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Attach the hold-down strap.
6. Verify that cables are properly routed.
7. Reinstall the left side panel.
146
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MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a Polaris Battery Tendert
charger (PN 2871076) or by charging about once a month to make up
for normal self-discharge. Battery Tendert can be left connected dur-
ing the storage period, and will automatically charge the battery if the
voltage drops below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Do not ever pry the sealing strip off or
add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
147
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MAINTENANCE
Battery
Battery Charging
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until the battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger,
use the following guidelines for recharging.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
NOTE: Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
(Using constant current
Voltage
Action
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None, check at 3
mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
3-6 hours
charge given,
check in 3 months
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
Needs charge
Needs charge
5-11 hours
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
148
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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 151 for the part numbers of Polaris prod-
ucts.
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 snowmobile 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.
Battery Maintenance
Remove the battery and recharge it as outlined on page 148. Store the
battery in a cool, dry place.
Controls and Linkage
Lubricate all bushings and cables at the intervals outlined in the Periodic
Maintenance Table beginning on page 100.
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 service manual. See your dealer.
149
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MAINTENANCE
Extended Storage
Engine Protection
Fogging the engine is not recommended for this model.
CAUTION
Fogging the engine improperly can result in damage to the sensors. Fogging
is not recommended.
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 snowmobile
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.
150
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POLARIS PRODUCTS
Description
Part No.
Engine Lubricants
2874865
2874866
2876244
2876245
Performance Synthetic 4-Stroke (PS-4) Oil (qt.)
Performance Synthetic 4-Stroke (PS-4) Oil (gal.)
Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.)
Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.)
Chaincase Lubricants
2873105
2872951
Synthetic Chaincase Lubricant (qt.)
Synthetic Chaincase Lubricant (12 oz.)
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season (3 oz.)
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Dielectric Grease (Nyogel™)
2871312
2871322
2871423
2871329
Coolant
2871323
2871534
Anitfreeze, 60/40 Premix (gal.)
Anitfreeze, 60/40 Premix (qt.)
Additives / Miscellaneous
2871326
2870652
2872189
2872893
2870505
2872889
2872890
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT4 Brake Fluid (12 oz.)
Engine Degreaser (12 oz.)
Isopropyl
Brake and Clutch Cleaner
Carburetor and Throttle Body Cleaner
151
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TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Speed, RPM or Boost is Limited
Probable Cause
Solution
See causes on page 38.
Engine Management System RPM
Reduction Mode is activated
Jammed clutch
Check for twisted belt or broken spring.
See your dealer.
Jammed track
Remove any foreign objects. Slider may
be melted to the track clips due to lack of
lubrication. Track may be iced up or fro-
zen to the ground.
Jammed or broken chaincase sprocket or See your dealer.
chain
Mechanical failure
See your dealer.
Engine Doesn't Turn Over
Probable Cause
Solution
Low battery voltage
Recharge the battery to 12.8 VDC.
Check all connections and tighten.
Check all connections and tighten.
Lift the stop switch to the ON position.
See your dealer.
Loose battery connections
Loose solenoid connections
Engine stop switch is off
Fusible link malfunction
Fuse panel malfunction
Check condition of fuses. Replace blown
fuses, then see your dealer.
Main relay panel malfunction
Mechanical failure
See your dealer.
See your dealer.
152
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TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Turns Over, Fails to Start
Probable Cause
Solution
Out of fuel
Refuel.
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plugs
No spark to spark plug
Water or fuel in crankcase
Clogged fuel filter
See your dealer.
Replace with fresh recommended fuel.
Inspect plugs and replace if necessary.
See your dealer.
See your dealer.
Replace the filter.
Low battery voltage
Recharge the battery to 12.8 VDC.
See your dealer.
Poor engine compression
Mechanical failure
See your dealer.
Engine Backfires
Probable Cause
Solution
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Mechanical failure
Inspect, clean and/or replace spark plugs.
Set gap to specs or replace plugs.
Replace with fresh recommended fuel.
See your dealer.
Loose ignition connections
Water present in fuel
Check all connections and tighten.
Replace with fresh recommended fuel.
Inspect and repair, or see your dealer.
Exhaust manifold leak
153
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TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Runs Irregularly, Stops or Loses Power
Probable Cause
Solution
See causes on page 38.
Engine Management System RPM
Reduction Mode is activated
Low battery voltage
Recharge the battery to 12.8 VDC.
See your dealer.
Water is present in fuel
Poor quality or low octane fuel
Loose ignition connections
Incorrect spark plug gap or heat range
Fouled or defective spark plug
Kinked or plugged fuel vent line
Clogged air filter
Replace with fresh recommended fuel.
Check all connections and tighten.
Set gap to specs or replace plug.
Inspect, clean and/or replace spark plug.
Inspect and replace.
Inspect and clean or replace.
Air flow through intake is too warm
(Turbo models)
Boost is limited until cooler air flows
through the intake.
Engine management system failure
Engine overheating
See your dealer.
Stop and cool the engine. See the “Engine
Overheating” troubleshooting section on
page 155.
Fuel in crankcase
See your dealer.
Drive clutch binding
Incorrect clutching
See your dealer.
See your dealer.
Driven clutch malfunction
Worn drive belt
See your dealer.
Replace with the recommended belt.
See your dealer.
Excessive belt/sheave clearance
Loose torque stop
Inspect and adjust.
See your dealer.
Other mechanical failure
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TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Overheating
Probable Cause
Solution
Inadequate snow conditions
Stop and cool the engine. Drive into snow
frequently to prevent overheating. See
page 21.
Low coolant
Stop and cool the engine. Check the cool-
ant level. See page 123. Check for leaks.
Bleed the system if the coolant level is
extremely low.
Restricted air flow to radiator
Stop and cool the engine. Clean snow and
debris from the radiator.
Harsh Drive Clutch Engagement
Probable Cause
Solution
Worn drive belt
Replace with the recommended belt.
See your dealer.
Excessive belt/sheave clearance
Drive Belt Turns Over
Probable Cause
Solution
Incorrect belt
Replace with the recommended belt.
See your dealer.
Incorrect clutch alignment
Broken or loose engine mount
See your dealer.
Drive System Noise
Probable Cause
Solution
Broken drive clutch components
See your dealer.
See your dealer.
Bearing failure (chaincase, jackshaft or
front drive shaft)
Flat spots on drive belt surface
Loose drive chain
Inspect and replace as needed.
Inspect and adjust (or replace).
See your dealer.
Worn drive chain/broken sprocket teeth
155
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TROUBLESHOOTING
IQ Comfort Suspension Troubleshooting
Problem
Solution
Rear suspension bot-
toms too easily
• Adjust torsion spring preload to achieve proper static sag
(see page 58).
• Change torsion spring to stiffer optional spring (see your
dealer).
• Rotate RRSS to higher position (see page 62).
Rides too stiff in rear • Check for binding suspension shafts and grease all pivot
points.
• Adjust torsion spring preload to achieve proper static sag
(see page 58).
• Change torsion spring to softer optional spring (see your
dealer).
• Check track tension (see page 140).
• Rotate RRSS to lower position (see page 62).
Machine darts from
side to side
• Check ski alignment (see page 144).
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Ensure skags are straight on skis.
• Set static sag (see page 58).
• Check rail slide/replace if worn (see page 142).
• Install Accu-Trak dual skags (see your dealer).
Front end pushes
• Check for worn skags.
• Check for binding front suspension shafts and steering
components, grease all pivot points (elevate front of
machine).
• Set static sag (see page 58).
• Install single skag (see your dealer).
• Increase IFS preload (if equipped) (see page 55).
• Rotate RRSS to higher position (see page 62).
Steering is heavy
• Make sure spindles and all steering components turn freely.
• Check ski alignment (see page 144).
• Check skags and skis for damage.
• Set static sag (see page 58).
156
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TROUBLESHOOTING
M-10 Suspension Troubleshooting
Problem
Solution (Perform only one change at a time)
Rear suspension
bottoms too easily
• Increase FRA position (see page 65).
• Install appropriate optional center retainer on rear track shock
(see page 66).
• Increase front track shock coil spring preload by adding
washers.
• Revalve rear track shock compression damping (see your
dealer).
• Check track tension (see page 140).
Rear suspension
rides too stiff
• Decrease FRA position (see page 65).
• Install appropriate optional center retainer on rear track shock
(see page 66).
• Decrease front track shock coil spring preload by adding
washers.
• Revalve rear track shock compression damping (see your
dealer).
• Check track tension (see page 140).
Front end pushes
Steering is heavy
• Check for worn skags
• Check for binding suspension shafts and grease all pivot
points.
• Shorten front limiter strap.
• Install single skags (see your dealer).
• Check skags and skis for damage.
• Check ski alignment (see page 144).
• Make sure spindles and all steering components turn freely.
• Verify sag dimension (see page 63). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
• Adjust IFS preload (see page 55).
• Adjust RIDER SELECT (see page 34).
Machine darts from • Check ski alignment (see page 144).
side to side
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Make sure skags are straight on skis.
• Set static sag (see page 63).
• Install dual skags.
157
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TROUBLESHOOTING
Drive Belt Wear/Burn
Cause
Solution
Driving at low
RPM
Drive at higher RPM. Gear the machine down. Check belt
deflection.
Insufficient warm- Warm the engine at least five minutes. Take the drive belt off
up
the machine in extremely cold weather and warm it up. Break
machine loose from the snow.
Towing at low
RPM
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 ambi-
ent temperatures. Check for snow ingestion.
Ice and snow build- Warm the engine at least five minutes. Take the drive belt off
up between track
and tunnel
the machine in extremely cold weather and warm it up. Break
machine loose from the snow.
Poor engine perfor- Check for fouled plugs or water, ice, or dirt in the gas tank or
mance fuel line.
Loading machines Skis may gouge into trailers and prevent the drivetrain from
onto trailers
spinning properly. Use enough speed to drive the machine com-
pletely onto the trailer. Push and pull it to finish loading if nec-
essary.
Clutch malfunction Inspect clutch components. See your dealer.
Slow, easy clutch
engagement
Use fast, aggressive throttle to engage clutch.
Wrong or missing
belt
Always use the recommended belt.
Improper break-in Always break in a new belt and/or clutch by avoiding aggres-
sive or high speed operation during the break-in period.
158
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WARRANTY
Service And Warranty Information
Obtaining Service and Warranty Assistance
Read and understand the service data and the Polaris warranty informa-
tion contained in this manual. Contact your Polaris dealer for replace-
ment 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
2. Model number
3. Dealer name
4. Date of purchase
5. Details of trouble experienced
6. Length of time and conditions of operation
7. Previous correspondence
Use the page provided near the front of your Owner’s Manual to record
the identification numbers of your snowmobile and its engine.
Polaris Customer Service
United States: 1-763-417-8650
Canada: 1-204-925-7100
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WARRANTY
Service And Warranty Information
Polaris Anti-Theft System
The Polaris anti-theft system (PATS) monitoring program is designed to
aid owners of registered snowmobiles in recovery of stolen machines.
Administration
1. Polaris snowmobile owner reports theft.
A. In addition to notifying the proper law enforcement officials, the
owner must call Polaris Customer Service.
B. Owners must provide their name, address, telephone number and
the model and serial number of stolen machines.
2. Polaris warranty will provide all dealerships with a monthly updated
list of all stolen units to further monitor thefts.
3. Polaris warranty will aid in notifying the proper owner when a unit
is recovered
160
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WARRANTY
Limited Warranty
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-
ITED WARRANTY on all components of the Polaris snowmobile against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. The warranty begins on
the date of purchase. This warranty is transferable to another consumer, during the war-
ranty period, through a Polaris dealer.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
set-up will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures not caused by a defect in material or workmanship.
The warranty does not cover accidental damage, normal wear and tear, abuse or
improper handling. The warranty also does not cover any snowmobile that has been
structurally altered, neglected, improperly maintained, used for racing or used for pur-
poses other than for which it was manufactured. The warranty does not cover any dam-
ages that occur during trailer transit or as a result of unauthorized service or parts. In
addition, this warranty does not cover physical damage to paint or finish, stress cracks,
tearing or puncturing of upholstery material, corrosion or defects in parts, components
or the snowmobile due to fire, explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,
repair or replacement of any defective materials, or components or products. THE REM-
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-
sion or limitation of incidental or consequential damages or implied warranties, so the
above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations
on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controlling state law.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris snowmobiles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (The cost of transportation to
and from the dealer is YOUR responsibility). Polaris recommends that you use your
original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Your dealer will contact the
appropriate personnel at Polaris if additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
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WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested
by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle
Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer
sign the PDI form prior to delivery may void the warranty. Failure to provide proof of
required periodic maintenance upon request may result in denial of warranty coverage.
Use of the recommended Polaris products for lubrication and maintenance as directed by
the Owner’s manual is highly recommended. Should a failure occur during the warranty
period resulting from the use of non-recommended products, warranty coverage may be
denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty con-
sideration if the failure was due to wear or not the direct result of a defect:
Skis
Ski wear rods
Tracks
Slide rails
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered “consumable,” meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Filters
Fuel
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Sealants
Hotel fees
Meals
Towing charges
Mileage
Rentals/Loss of product use
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
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WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused snow-
mobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is transfer-
able 120 days after the original purchase date, free of charge, through any Polaris snow-
mobile dealer. Coverage on Snow Check units is automatic. Although you do not
receive a warranty card, your dealership should have printed a copy of the warranty reg-
istration form. This form is your proof of warranty.
Consumer Exclusions
• Each repair visit after the first twelve months of standard warranty coverage is subject
to a $50 deductible.
• The free Second Year Engine Service Contract applies to the first 5,000 miles or two
(2) calendar years from date of purchase, whichever comes first. Tampering with the
odometer shall void all warranties/service contracts. No extensions to coverage under
this engine service contract can be given. Used snowmobiles are not eligible under this
program.
• Snowmobiles used for commercial purposes or for racing are excluded from coverage.
Coverage
Coverage for second year engine failures due to defects in materials and workmanship
will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-
tional paperwork required. The free Second Year Engine Service Contract is subject to a
$50 deductible per visit. Regular, documented service maintenance visits are required to
validate this warranty.
A partial list of items excluded from coverage includes:
• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ 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.
• Failure due to unauthorized service.
• Failures due to lack of service as required in the owner’s manual or Polaris updates.
This includes off-season storage as listed in the owner’s manual.
• Failure due to use of unauthorized parts or modifications.
• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and
exhaust manifolds excluding paint coverage.
• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring
and other electrical components are excluded from coverage.
• Cooling system coverage is limited to the water pump assembly and components, fan,
fan bearings, temperature sensor, gasket and seals.
• Non wear related throttle body parts are covered. The fuel pump is covered.
• Clutches and related clutch parts, including but not limited to, the drive belt, are
excluded from coverage.
• Electrical components are excluded from coverage.
• Gearcases and transmissions are excluded from coverage.
164
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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 159).
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WARRANTY
Snowmobile Engine Emissions Limited Warranty
This snowmobile engine emissions limited warranty is in addition to the Polaris stan-
dard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time
it is first purchased, this emissions-certified snowmobile engine meets current U.S.
Environmental Protection Agency regulations applicable to snowmobile emissions
under 40 CFR1051, 1065 and 1068.
Polaris warrants that the engine is free from defects in materials and workmanship that
would cause it to fail to meet these regulations. The warranty period for this emissions
certified snowmobile engine starts on the date when the engine is first purchased and
continues for 4000 kilometers (2485 miles) of vehicle travel, 200 hours of operation, or
30 calendar months, whichever comes first.
This engine emissions limited warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. This includes compo-
nents whose failure increases the snowmobile engine's emissions. To the extent they are
present on your snowmobile engine, this includes electronic controls, fuel injection
components, exhaust-gas recirculation system components, and aftertreatment system
components. Replacing or repairing other components not covered by this warranty is
the responsibility of the snowmobile owner.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of Polaris, repair or replacement of any defective materials, components or prod-
ucts.
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-
TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WAR-
RANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE
LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN.
POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS
WARRANTY.
166
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WARRANTY
Snowmobile Engine Emissions Limited Warranty
Some states do not allow limitations on how long an implied warranty lasts, so the above
limitation may not apply if it is inconsistent with the controlling state law. This limited
warranty excludes failures not caused by a defect in material or workmanship. This lim-
ited warranty does not cover damage due to accidents, abuse or improper handling,
maintenance or use. This limited warranty also does not cover any engine that has been
structurally altered, or any engine that has been used in racing competition. This limited
warranty also does not cover physical damage, corrosion or defects caused by fire,
explosions or other similar causes beyond the control of Polaris.
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. Polaris can deny an emissions warranty claim if any specified critical
emissions-related maintenance is not performed. Performance of other scheduled main-
tenance is strongly recommended, but is not necessary to keep the emissions-related
warranty valid.
Any qualified repair shop or qualified person may maintain, replace, or repair the emis-
sion control devices or systems on your snowmobile. Polaris recommends that you con-
tact an authorized Polaris dealer to perform any service that may be necessary.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law and may result in civil penalties.
167
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MAINTENANCE LOG
Present this section of your manual to your dealer each time your snow-
mobile is serviced. This will provide you and future owners with an
accurate log of maintenance and services performed on the snowmobile.
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
1500 mi.
(2400 km)
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
169
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
170
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INDEX
A
D
Access Panel, Radiator Compartment 31
Accessories . . . . . . . . . . . . . . . . . . . . 71
Adjustable Steering System . . . . 34-36
Air Filter (Turbo)). . . . . . . . . . . . . . 120
Alternator Belt Inspection. . . . . . . . 120
Apparel . . . . . . . . . . . . . . . . . . . . . . . 12
Avalanches . . . . . . . . . . . . . . . . . . . . 17
Drive Chain Tension . . . . . . . . . . . 128
Driver Awareness. . . . . . . . . . . . . . . 16
Driveshaft Bearing Lubrication . . . 113
Driving Downhill . . . . . . . . . . . . . . . 18
Driving in Hilly Terrain . . . . . . . . . . 19
Driving on Slippery Surfaces . . . . . . 19
Driving Responsibly. . . . . . . . . . . . . 22
B
E
Backrest . . . . . . . . . . . . . . . . . . . . . . 30
Battery . . . . . . . . . . . . . . . . . . 146-148
Charging . . . . . . . . . . . . . 147-148
Electrical System . . . . . . . . . . . . . . 133
Emission Control Information . . 97-98
Emission Control Label . . . . . . . . . . 97
Emission Control Maintenance . . . . 97
Engine Management System . . . 37-39
Engine Oil. . . . . . . . . . . . . . . . 103-111
Engine Stop Switch . . . . . . . . . . . . . 92
Environment, Preservation. . . . . . . . . 6
Exhaust System . . . . . . . . . . . . . . . 121
Eye Protection . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . 146
Removal . . . . . . . . . . . . . . . . . 146
Storage . . . . . . . . . . . . . . . . . . 147
Battery Replacement, MFD . . . . . . . 52
Brake Components . . . . . . . . . . . . . 129
Brake Fluid . . . . . . . . . . . . . . . . . . . 130
Brake Inspection . . . . . . . . . . . . . . . 129
Brake Lever Feel. . . . . . . . . . . . . . . . 77
Brake Lever Travel . . . . . . . . . . 77, 129
Brake System Bleeding. . . . . . . . . . 131
Brakes . . . . . . . . . . . . . . . . 77, 129-131
Break-In Period. . . . . . . . . . . . . . . . . 84
Bulbs, Replacing. . . . . . . . . . . . . . . 132
F
FRA Position, M-10 . . . . . . . . . . . . . 65
Front Rear Scissor Stop . . . . . . . . . . 60
Front To Rear Coupling . . . . . . . . . . 60
FRSS. . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuel Filter . . . . . . . . . . . . . . . . . . . . 119
Fuel Injectors . . . . . . . . . . . . . . . . . 119
Fuel Level. . . . . . . . . . . . . . . . . . . . . 89
Fuel Lines. . . . . . . . . . . . . . . . . . . . 119
Fuel Pump. . . . . . . . . . . . . . . . . . . . 119
Fuel Safety . . . . . . . . . . . . . . . . . . . . 83
Fuel System Deicers. . . . . . . . . . . . . 89
Fuse Label . . . . . . . . . . . . . . . . . . . 133
C
Cargo Bag (Cruiser) . . . . . . . . . . . . . 32
Cargo Bag (Touring). . . . . . . . . . . . . 31
Cargo Overload. . . . . . . . . . . . . . . . . 14
Clutch Alignment Offset. . . . . . . . . 134
Clutch Center Distance . . . . . . . . . . 134
Clutch Cover Warning . . . . . . . . . . . 24
Clutch System. . . . . . . . . . . . . 134-137
Clutches . . . . . . . . . . . . . . . . . . . . . . 20
Coolant . . . . . . . . . . . . . . . . . . . . . . 122
Coolant High Temperature Light . . 124
Coolant Level . . . . . . . . . . . . . . . . . 123
Cooling System. . . . . . . . . . . . 122-127
Cooling System Bleeding . . . . 125-127
Cooling System Flushing . . . . . . . . 125
G
Gauge Cleaning . . . . . . . . . . . . . . . . 53
Gearcase Oil . . . . . . . . . . . . . . 115-116
Gearcase Oil Change . . . . . . . . . . . 116
Gearcase Oil Check . . . . . . . . . . . . 115
Grab Handle Adjustment . . . . . . . . . 33
D
H
DC Outlet, 12-Volt . . . . . . . . . . . . . . 33
Digital Display . . . . . . . . . . . . . . . . . 41
Disabled Operators . . . . . . . . . . . . . . 14
Drive Belt. . . . . . . . . . . . . 20, 135-137
Adjustment . . . . . . . . . . . . . . . 135
Condition . . . . . . . . . . . . . . . . 135
Deflection . . . . . . . . . . . . . . . . 135
Installation . . . . . . . . . . . . . . . 137
Removal . . . . . . . . . . . . . . . . . 136
Handlebar Adjustments . . . . . . . . . . 70
Headlight Adjusting . . . . . . . . . . . . . 31
Helmet . . . . . . . . . . . . . . . . . . . . . . . 12
High Temperature Indicator Light . 124
Hood Latches . . . . . . . . . . . . . . . . . . 76
171
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INDEX
I
R
Ice and Snow Build-up . . . . . . . . . . 18
IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Instrumentation . . . . . . . . . . . . . . 41-53
Intake Filters . . . . . . . . . . . . . . . . . 119
Intake Silencer . . . . . . . . . . . . . . . . . 20
Rail Slide Wear . . . . . . . . . . . . . . . . 142
Rear Rear Scissor Stop . . . . . . . . . . . 61
Rear To Front Coupling . . . . . . . . . . 61
Relay Label . . . . . . . . . . . . . . . . . . . 133
Retainers, Optional, M-10. . . . . . . . . 66
Reverse Operation. . . . . . . . . . . . 94-95
Reverse Warning. . . . . . . . . . . . . . . . 26
Rider Capacity. . . . . . . . . . . . . . . . . . 13
RIDER SELECT . . . . . . . . . . . . . 34-36
RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 61
J-K
Jump-Starting. . . . . . . . . . . . . . . . 86-88
Knock Sensor (Turbo Models) . . . . 40
L
S
Lamps, Replacing . . . . . . . . . . . . . 132
Light, High Temperature Indicator 124
Lights. . . . . . . . . . . . . . . . . . . . . . . 132
Lubrication. . . . . . . . . . . . . . . . 113-114
Safety. . . . . . . . . . . . . . . . . . . . . . . 8-23
Safety Decals. . . . . . . . . . . . . . . . 24-27
Sag, M-10 . . . . . . . . . . . . . . . . . . 63-68
Seat Latches . . . . . . . . . . . . . . . . . . . 75
Shock Spring Preload, Front . . . . . . . 55
Shock Valving. . . . . . . . . . . . . . . . . . 56
Skags . . . . . . . . . . . . . . . . . . . . . 73, 145
Ski Alignment . . . . . . . . . . . . . . . . . 144
Ski Pressure, M-10 . . . . . . . . . . . 67-68
Snow Build-up . . . . . . . . . . . . . . . . . 18
Snow Conditions . . . . . . . . . . . . . . . . 21
Spark Plugs . . . . . . . . . . . . . . . 117-118
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 15
Spring Preload, IQ. . . . . . . . . . . . . . . 58
Spring Preload, M-10 . . . . . . . . . . . . 66
Springs, Front . . . . . . . . . . . . . . . . . . 56
Starting the Engine . . . . . . . . . . . . . . 85
Starting, Emergency . . . . . . . . . . 86-88
Steering Inspection . . . . . . . . . . . . . 143
Steering System. . . . . . . . . 76, 143-145
Stop Switch . . . . . . . . . . . . . . . . . . . . 92
Stopping . . . . . . . . . . . . . . . . . . . . . . 95
Storage, Daily . . . . . . . . . . . . . . . . . . 96
Storage, Extended . . . . . . . . . . 149-150
Studs . . . . . . . . . . . . . . . . . . . . . . . . . 72
Survival Preparation . . . . . . . . . . . . . 11
Suspension Adjustment
M
Maintenance Interval Table. . . 100-102
Maintenance Program . . . . . . . . . . . 99
Malfunction Indicator Lamp . . . . . . 37
Maneuverability. . . . . . . . . . . . . . . . 20
MFD Battery Replacement . . . . . 52-53
MFD Components . . . . . . . . . . . . . . 41
MFD Digital Display Programs. . 44-52
MFD Settings. . . . . . . . . . . . . . . . 42-43
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . 6
O
Oil
Engine . . . . . . . . . . . . . . . 103-111
Gearcase. . . . . . . . . . . . . . 115-116
Oil Breather Element. . . . . . . . . . . 112
Oil Breather Filter . . . . . . . . . . . . . 120
Oil Change. . . . . . . . . . . . . . . . 108-111
Oil in System Check . . . . . . . . . . . 107
Oil Level Check. . . . . . . . . . . . 104-106
Operating in Deep Snow . . . . . . . . . 21
Operation Warning . . . . . . . . . . . . . 27
Switch (M-10 ACE) . . . . . . . . . 30
M-10 ACE. . . . . . . . . . . . . . . . . 42
Cruiser. . . . . . . . . . . . . . . . . . . . 69
P
Front . . . . . . . . . . . . . . . . . . 54-56
IQ. . . . . . . . . . . . . . . . . . . . . 58-62
Parking Brake Lever Lock. . . . . . . . 78
Passenger Seat (Cruiser) . . . . . . . . . 32
Passenger Seat (Touring). . . . . . . . . 30
Passenger Warning . . . . . . . . . . . . . 25
PS-4 Oil . . . . . . . . . . . . . . . . . . . . . 103
Polaris Products . . . . . . . . . . . . . . . 151
Pre-Ride Checklist. . . . . . . . . . . 74, 82
Pressure Cap Warning . . . . . . . . . . . 24
M-10 . . . . . . . . . . . . . . . . . . 63-68
M-10 ACE. . . . . . . . . . . . . . 52, 69
Rear . . . . . . . . . . . . . . . . . . . 57-69
Suspension Coupling, IQ . . . . . . . . . 60
Suspension Inspection. . . . . . . . . . . . 80
Suspension Lubrication, Front . . . . 113
Suspension Lubrication, Rear . . . . . 114
172
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INDEX
S
T
Suspension Performance Tips. . . . . . 57
Suspension Set-up Chart, M-10 . . . . 68
Suspension, Front . . . . . . . . . . . . . . . 54
Switch
Traction Products . . . . . . . . . . . . 72-73
Transporting the Snowmobile . . . . 150
Troubleshooting
Drive Belt Wear/Burn . . . . . . 158
Engine and Drive Train . 152-155
IQ Suspension. . . . . . . . . . . . . 156
M-10 Suspension . . . . . . . . . . 157
Trunk (Cruiser). . . . . . . . . . . . . . . . . 32
Turbo Noise (FST) . . . . . . . . . . . . . . 93
Stop Switch. . . . . . . . . . . . . . . . 92
Suspension Adjustment Switch 30
Throttle Safety Switch . . . . . . . 92
T
Throttle Cable Lubrication . . . . . . . 113
Throttle Lever . . . . . . . . . . . . . . . 75, 93
Throttle Safety Switch . . . . . . . . 75, 92
Tip-Over Inspections . . . . . . . . . . . . 82
Torsion Spring Preload, IQ. . . . . . . . 59
Towing . . . . . . . . . . . . . . . . . . . . . . . 96
Track Alignment. . . . . . . . . . . . . . . 142
Track Inspection . . . . . . . . . . . . 79, 138
Track Lubrication . . . . . . . . . . . . . . 139
Track Replacement . . . . . . . . . . . . . 138
Track Tension . . . . . . . . . . . . . 140-141
Track Warm-Up . . . . . . . . . . . . . 90, 91
Track Warning . . . . . . . . . . . . . . . . . 25
V
Vehicle Identification Numbers . . . . . 7
W
Warning Labels/Decals . . . . . . . 24-27
Warranty, Engine Emissions . 166-167
Wear Strips. . . . . . . . . . . . . . . . . . . . 73
Weight Transfer . . . . . . . . . . . . . . . . 62
Windchill/Temperature Charts. . . . . 23
173
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