Polaris Offroad Vehicle 550 Transport User Manual

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WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris enthusiasts. Be sure to visit us online at

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

tions, upcoming events, career opportunities and more.

Here at Polaris we proudly produce an exciting line of utility and recre-

ational 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!

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

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.

2009 550 Transport/Trail Touring Deluxe Owner's Manual

P/N 9921592

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

This section contains helpful information for owners and drivers and

illustrates the location of important identification numbers that should

be recorded in the owner's manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

This section describes safe vehicle operation and identifies warning

decals and their locations.

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

This section identifies the locations of your snowmobile's controls and

features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 29

This section explains how to tailor the suspension and other features for

an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 45

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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

bile's regular maintenance.

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 113

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 114

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 130

Record maintenance and service in the log for your reference and for

future owners of the vehicle.

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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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:____________________________________________________

(right front side of engine crankcase)

Key Number: ___________________________________________________________

Important Notes for Owners and Drivers

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

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

sold.

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.

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.

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INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam-

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

grams that encourage protection of our environment, including wildlife

and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The

Society of Automotive Engineers (SAE), the standard-setting body for

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards.

Our muffler systems are designed to reduce noise levels and must not be

altered or removed. The sound of your snowmobile may not be welcome

to non-snowmobilers, so you have a responsibility to operate your

snowmobile with concern for others. We do our part by manufacturing

quieter machines; we ask your help to further reduce the impact of noise

by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission lev-

els of two-stroke engines. We expect our efforts to lead to the reduction

of potential air pollution.

In addition to our technological research, we encourage government

agencies, manufacturers, distributors, dealers, ecologists, and other

interested parties to work together to develop data on environmental

topics.

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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.

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SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 72

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

are thoroughly inspected by your dealer at specific mileage intervals.

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or

use drugs or medications before or while driving or riding as a passenger.

They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to

ensure operator safety. Make sure your snowmobile is in excellent operating

condition at all times. Always check major and vital safety components

before every ride.

All Polaris snowmobiles are designed and tested to provide safe operation

when used as directed. Failure of critical machine components may result

from operation with any modifications, especially those that increase speed

or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may

become aerodynamically unstable at speeds higher than those for which it is

designed. Loss of control may occur at higher speeds. Modifications may

also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has

been added, or any modifications have been made, to increase the speed or

power of the snowmobile.

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SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially

exposed for proper operation.

WARNING

Serious injuries may result if hands, feet, or

clothing become entangled in the track. Be

alert when riding, and remain properly

seated to stay clear of the track.

Never hold the snowmobile up or stand

behind it while warming up the track. A

loose track or flying debris could cause

serious injury or death. We recommend

having your dealer perform all track service

and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the igni-

tion, raise the hood, make the adjustment, secure shields and guards,

secure the hood, and then restart the engine to check its operation.

WARNING

Serious injury can occur if fingers or clothing contact the moving parts of an

engine. Always stop the engine before attempting adjustments.

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SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be comfortable

when riding. Be aware of the weather fore-

cast, especially the windchill, and dress

accordingly. See the chart on page 21.

WARNING

Avoid wearing loose clothing or long

scarves, which can become entangled in

moving parts and cause serious injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds 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

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.

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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 and the features available on

some snowmobiles, but under many conditions, the proper position is to

be seated with both feet on the running boards and both hands on the

handlebar grips for proper throttle, brake and steering control.

NOTE: Use of a backrest may hinder your weight shifting ability. This

could affect your ability to control this rider-active vehicle in cer-

tain extreme driving situations.

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.

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

all times:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Winter Survival Kit

• Trail Map

• Owner's Manual

• First Aid Kit

• Extra Oil

• Fuel Deicer

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SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and

physical skills. Operators with cognitive or physical disabilities have an

increased risk of loss of control, which could result in serious injury or

death.

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.

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 “jump-

ing" your snowmobile.

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. See page 23 for decal

location.

Machines 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 machine 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.

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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 laws governing snowmobile operation and speed

limits. Always be alert and pay attention to the trail ahead. Multiplying

speed (MPH) by 1.5 will equal the approximate number of feet per sec-

ond your machine travels. If your speed is 40 MPH, your machine is

traveling about 60 feet per second. If you look back for only two sec-

onds, your machine will travel about 120 feet. If your speed is 60 MPH,

your machine will travel about 180 feet in two seconds.

Traveling at night requires extra caution. Check headlight and taillight

to ensure proper operation, and don't over-drive your headlight beam.

Always be able to bring your machine to a stop in the distance illumi-

nated by the headlight.

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SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,

posts, or other obstacles. Be especially

alert if you're snowmobiling after dark.

Always be on the alert for wire fences.

Single strands are especially dangerous,

since there may be a great distance

between posts. Guy wires on utility poles

are also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways.

The noise of your machine will drown out

the sound of approaching vehicles. Look

ahead, behind, and to both sides before

turning or crossing railroad tracks or high-

ways. Steep embankments may also hide

your view. Always leave yourself a way

out.

R R

Variances in snow depth and/or water currents may result in uneven ice

thickness. You may drown if you break through the ice. Avoid travelling

on frozen bodies of water.

When teaching inexperienced operators to ride, set up a predetermined

course for practice. Make sure they know how to drive and control the

snowmobile before allowing them to make longer trips. Teach them

proper snowmobile courtesy, and enroll them in driver's training and

safety courses.

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SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly

trained and equipped before traveling in

mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped

with a shovel, probe and avalanche

beacon.

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

Be aware that all of the snow is connected. You may be riding on a flat

slope or snow covered road, but if the snowpack above is unstable

enough you can trigger an avalanche on a steeper slope above you.

Always be aware of snow conditions above you as you travel in moun-

tainous terrain.

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

lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi-

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

and Canadian online avalanche centers at www.avalanche.org.

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SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

Ice and snow build-up may interfere with the steering of your machine, result-

ing in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice

and snow are not interfering with full left and right steering. If difficulty

is encountered, remove ice and snow build-up that may be obstructing

the steering linkage.

Driving on Slippery Surfaces

WARNING

Driving on ice or hard-packed snow reduces steering and braking control,

which may result in loss of control and serious injury or death. Never attempt

an abrupt change of direction when operating on slippery surfaces. Slow

down and use extra caution when operating on slippery surfaces.

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SAFETY

Operator Safety

Driving Downhill

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

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

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

machine and keep it from rolling freely downhill.

WARNING

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

may cause the brake system to overheat, which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will also cause

an overheated brake system. This condition may lead to a sudden loss of

brakes and/or fire and may result in serious injury or death.

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SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance

and machine roll-over, causing serious injury or death. Use caution and good

judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is

unavoidable, keep your weight low and forward. If you must cross the

face of a slope, keep your weight on the uphill side of the machine to

maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to

obstacles, sharp drops or other people or vehicles that may be on the

other side of the hill.

If you're unable to continue up a hill, turn the machine downhill before

it loses momentum. If this isn't possible, spin the track just enough to

dig in to prevent it from rolling back down the hill. Stop the engine and

set the parking brake (if equipped). Keeping away from the downhill

side of the machine, pull the rear of the snowmobile around and point

the front end and skis downhill. Remount the machine, restart the

engine, release the parking brake, and descend the hill carefully.

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.

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SAFETY

Operator Safety

Clutch Guard

Do not operate the engine with the clutch guard removed.

The clutch guard is designed to protect the operator from metal parts if

the clutch should fail. Although the chance of failure is extremely

remote, don't defeat the purpose of the safety guard by removing it.

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 machine into motion, but always operate within

safety limits.

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

machines designed to carry a load.

Maintenance

Follow the recommended maintenance program beginning on page 72

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

are thoroughly inspected by your dealer at specific mileage intervals.

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SAFETY

Operator Safety

Inadequate Snow Conditions

Moveable hood closures are included on some Polaris snowmobiles.

They are normally left open and are located on the front upper and lower

hood openings. If operating in deep snow or in extreme cold conditions

(below -20_ F), Polaris recommends closing the upper hood closure.

WARNING

Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could

cause irreversible track damage and lead to serious injury.

Since snow provides the only lubrication for the power slide suspension

and, on liquid cooled models, cooling for the engine, adequate snow

cover is a requirement for operation of your machine. Driving in too lit-

tle snow will result in excessive wear and damage to the slide rail, track

and/or engine.

If the machine becomes stuck in snow, clear the running board area of

snow, then step down the snow in front of the machine so that when the

throttle is opened, the snowmobile will be able to climb up and over the

snow.

CAUTION

When operating on icy surfaces or hard-packed snow, avoid overheating the

slide rail and track. Lack of lubrication and cooling will cause overheating of

the slide rail and track, resulting in premature wear and failure. If frequently

operating in low cooling conditions, see your dealer for an optional wheel kit

that will reduce the wear from overheating.

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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.

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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.

WINDCHILL CHART (_F)

Wind

Speed

Actual Thermometer Reading (_F)

40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45

Equivalent Temperature (_F)

-5 -10 -15 -20 -25 -30 -35 -40 -45

-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

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

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

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

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

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

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

29 23 16

28 22 15

28 21 14

27 20 13

26 19 12

25 18 11

25 17 10

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

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

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

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

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

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

WINDCHILL CHART (_C)

Wind

Speed

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

KPH

Calm

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

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

-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62

-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

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

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SAFETY

Safety Decals and Locations

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

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

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

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

instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your Polaris dealer

to purchase a replacement. Replacement safety decals are 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 engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself -- see your dealer.

Air Box Warning

This warning decal is found under the hood on applicable models:

CAUTION

Do not operate above 40 mph with hood-to-air box foam removed

or engine failure will result.

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SAFETY

Safety Decals and Locations

Track Warning

The track warning decal is on the

rear of the tunnel:

WARNING

Stay clear of track. Do not sit on

seat back. Entanglement with the

track or a fall from seat back can

result in severe injury or death.

Passenger Warning

Polaris touring models are

designed for the operator and

one passenger. For more infor-

mation on operating with a pas-

senger, see page 11.

The passenger warning decal is

located at the right side of the

steering post:

WARNING

This vehicle is designed for

operator and ONE passenger

only.

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SAFETY

Safety Decals and Locations

Electronic Reverse Warning

Polaris snowmobiles equipped

with electronic reverse have a

reverse warning decal on the

lower dash:

WARNING

Reverse operation, even at low

speeds, can cause loss of con-

trol resulting in serious injury

or death. To avoid loss of con-

trol, always:

• Look behind before and

while backing up.

• Avoid sharp turns.

• Shift to or from reverse only

when stopped.

• Apply throttle slowly.

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.

• Elevation setting (above 6000 feet): push and hold for longer than 5

seconds to set. Let go of button at desired setting-fast flash for high

elevation, slower flash for low. Setting will remain until changed.

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SAFETY

Safety Decals and Locations

Operation Warning

The operation warning decal is located on the console:

WARNING

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

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

tact a Polaris dealer for a replacement.

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

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

caution when operating in unfamiliar terrain.

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

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

avoid unexpected obstacles, or to stop safely.

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

cle.

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

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

pull the brake lever to stop.

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

clothing while operating this vehicle.

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

requirements.

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

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

passenger reduces your ability to control the vehicle.

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

steering and braking ability are greatly reduced. Reduce speed and

allow extra space to turn or stop.

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

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

Owner's Manual for proper use of traction products.

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

of braking ability.

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

brake engaged for more than five minutes.

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

proper operation. Make sure hood is latched. Be seated and in posi-

tion to control the vehicle.

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

refueling.

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FEATURES

Some Polaris snowmobiles are equipped with special features. Operat-

ing controls and special feature controls are illustrated on this page. Not

all models come with all special features. See your Owner's Manual

Supplement.

General

Representation

1. Fuel Filler Cap

2. Ignition Switch

3. Brake Lever

4. Speedometer

5. Tachometer

6. Engine Stop Switch

7. Throttle Control

8. Hood Hold-Down Straps

9. Choke

10. Recoil Starter Handle

11. Parking Brake Lock

12. Handlebar Grip Warmer Switch

13. Thumbwarmer Switch

14. Electronic Reverse Button

15. Headlight Dimmer Switch

16. Low Oil Level Indicator (550)

17. Reverse Indicator (550)

18. High Beam Indicator (550)

550 Transport

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FEATURES

Trail Touring Shown

1. Front Bumper (do not use for pulling

or dragging the snowmobile)

2. Hood

3. Headlight

4. Windshield

5. Handlebar

6. Operator Seat

7. Passenger Grab Handle

8. Passenger Seat

9. Passenger Backrest

10. Suspension

11. Track

12. Trailing Arm

13. Nosepan

14. Ski

15. Taillights

16. Rear Bumper

17. Snow Flap

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FEATURES

Backrest

The backrest is adjustable for either

operator or passenger use.

Raise/Lower

1. Loosen the upper adjustment

knobs to raise or lower the

backrest.

2. Loosen the lower adjustment

knobs to move the backrest

forward for operator use or

rearward for passenger use.

Operator/Passenger

3. Always tighten the knobs

securely after adjusting.

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THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for about 150 miles (240 km) before making

any fine-tuning adjustments.

Settings will vary from rider to rider, depending on rider weight, vehicle

speed, riding style, and trail conditions. We recommend starting with

factory settings and then customizing each adjustment individually to

suit rider preference. The machine should be methodically tested, one

change at a time, under the same conditions (trail and snow conditions,

vehicle speed, riding position, etc.) after each adjustment until the best

ride is achieved.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

• Toe (ski alignment) (see

page 102)

• Camber (see your dealer)

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THE PERFECT FIT

Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page

102 to check alignment. If the skis are misaligned, see your dealer, as the

camber adjustment may also be affected.

For the best ride, the suspension should be adjusted to use the full travel

of the shocks with occasional light bottoming. To determine if your

machine is using full travel, push the jounce bumper down on the shock

rod until it contacts the body and test ride the machine. The bumper will

move up on the rod in relation to the amount of travel that was used dur-

ing the ride. If the travel is full, the bumper will be seated at the top of

the rod.

Shock Components

The front springs can be

changed if spring preload

alone isn't sufficient and

further adjustment is

desired to control suspen-

sion stiffness. See your

Polaris dealer for more

information.

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Pre-

load Adjuster Nut

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THE PERFECT FIT

Front Suspension Adjustments

Spring Preload

Increasing spring preload will increase

ski-to-ground pressure. Decreasing

spring preload will decrease ski-to-

ground pressure. When adjusting, be

sure the springs on both the left and right

sides of the machine are at the same

adjustment.

To increase front shock spring preload,

grasp the spring and turn it to the right.

Turn it to the left to decrease preload.

Increasing the spring preload too much

may adversely affect the handling of the

snowmobile and the performance of the

suspension. Never exceed one inch of

preload beyond the factory settings, and

ensure that both sides are adjusted the

Low

Preload

High

Preload

same. When decreasing preload, make sure at least two turns of preload

are holding the spring between the retainer on top of the shock and the

threaded spring preload adjuster nut on the shock body.

NOTE: Not all models have shocks with thread adjustable spring pre-

load. See your dealer for more information.

CAUTION

Always leave one thread showing above the adjuster nut. On models

equipped with a plastic adjuster nut, if the nut is unscrewed from the

threaded body, the nut will break.

Front Springs

For models without externally adjustable or revalvable shocks, the front

springs can be changed if spring preload alone isn't sufficient and fur-

ther adjustment is desired to control suspension stiffness. See your

Polaris dealer for more information.

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THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect

suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver

excellent performance for a given set of conditions. However, all sus-

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

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

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

tom out harshly on a snowcross course.

See your Polaris dealer for initial suspension setup information. Addi-

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

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

see your dealer.

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THE PERFECT FIT

Rear Suspension Adjustments

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With a

little experimentation, each rider can find a preferred setup. These

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

greatly affect the ride.

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

worn rail slide. It can also improve top speed.

• When riding on ice or hard-packed snow, adding a set of bogie wheels

to the rail may enhance the machine's performance. Bogie wheel kits

are available from your dealer.

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

dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce

moisture and rust build-up and ensure proper function of the

suspension components. Grease rear suspension pivots before

adjusting the rear suspension. See page 76.

Track Tension

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

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

tion beginning on page 98.

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THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the EDGE rear suspension

torsion spring preload, measure the

distance between the ground and

rear bumper. This is measurement

Take the first measurement with no

rider and with the rear suspension at

full extension.

NOTE: The rear bumper may need

to be lifted upward slightly

to fully extend the rear sus-

pension.

Next, have the rider drop down

hard on the seat and bounce up and

down several times, collapsing the

rear suspension. With the rider

seated, measure the distance

between the ground and the rear

bumper at the exact location used

for measurement X. This is mea-

surement Y.

To determine sag, commonly referred to as ride-in, subtract measure-

ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring

preload cams located on the rear torque arm. Use the illustration for ref-

erence. The ideal amount of Sag for the EDGE rear suspension is four

inches (X-Y=4).

If the rear suspension rides in less than three inches or more than five

inches with the torsion spring preload cams at their maximum range of

adjustment, optional torsion springs (softer or stiffer, respectively) may

be required. This is only an initial set-up, and final spring preload may

vary based on rider preference and riding conditions.

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THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Rear Spring Tension

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

the engine spark plug tool. Different rate torsion springs are available if

a firmer ride is desired. See your dealer for more information.

The following information is provided only as a guideline to be used for

initial suspension set-up. Your set-up may vary based on your desired

riding style.

Low Tension

Medium Tension

High Tension

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THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Indy Select Rear Shock

Some snowmobiles are equipped with the Indy Select rear shock, which

allows for adjustments to the compression valving. Locate the adjust-

ment screw near the base of the shock. In half-turn increments, turn the

screw clockwise to increase compression valving and stiffen the ride, or

counterclockwise to reduce compression and soften the ride. There are

approximately three full turns of adjustment available.

If bottoming continues after the screw has been turned fully clockwise,

the torsion spring should be adjusted (see page 35). Return the screw to

its original starting position after the torsion spring has been tightened.

Adjustment Screw

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THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Optional Torsion Springs

Different rate torsion springs are available for some shocks if a firmer

ride is desired. Contact your dealer for more information.

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.

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THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Suspension Coupling

Rear To Front Coupling and the Rear Rear Scissor Stop

(RRSS)

The rear rear scissor stop (RRSS) couples the movement of the rear

torque arm with the front torque arm and limits the amount of indepen-

dent movement between the rear torque and the front torque arm.

Adjusting the RRSS either allows more weight to transfer to the rear for

more traction, or allows less weight to transfer to the rear, resulting in

improved cornering performance. An adjustment dot is located on the

RRSS. This dot is on the longest end of the scissor stop.

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.

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THE PERFECT FIT

EDGE 136 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 condi-

tions.

To decrease weight transfer under

acceleration (for improved corner-

ing), rotate the RRSS to a higher

position.

Stock

To increase weight transfer or ski lift

during acceleration, move the RRSS

to the rearward hole on high posi-

tion. The RRSS may also be rotated

to a lower position for even more

weight transfer if desired.

Stock Position - This setting is most

desirable for trail riding.

Medium/High

Medium or High Position (standard

hole location) - This setting will

decrease weight transfer.

Rearward Upper Position

(optional hole location - This setting

will increase weight transfer.

Rearward Upper

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.

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THE PERFECT FIT

Handlebar Adjustment

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

1. Remove the handlebar cover

to expose the handlebar and

Cover

the four adjuster block bolts.

2. Using a 7/16-inch wrench,

loosen the four nuts on the

Bolts

bottom of the adjuster block

(turn the handlebar either left

or right for access to the rear

nuts).

NOTE: If necessary, pry the

blocks apart with a

screwdriver.

3. Adjust the handlebar to the

desired angle. Be sure the

handlebar, brake lever and

throttle lever operate

Nuts

smoothly and do not hit the

gas tank, windshield or any

other part of the machine when the handlebar is turned fully to the

left or right.

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

bolts to 11-13 ft. lbs. (15-18 Nm).

5. Reinstall the handlebar cover.

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THE PERFECT FIT

Traction Products

Studs

Before equipping your machine with traction products, be aware of the

laws in your area pertaining to the use of traction products. See your

dealer about installing studs and/or carbides. Many tracks with deep lug

designs cannot be studded, but your dealer will be able to offer advice

and assistance.

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 43.

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. The center of

the stud must be at least 1 1/8I (2.86 cm) from the outside edge of the track.

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Traction Products

nCarbide 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 103.

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

studs to maintain proper vehicle control. Maintain a proper balance

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

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

your dealer's track studding chart.

Inspect skags and studs frequently. Worn studs or skags may reduce

steering and braking control on hard-packed snow and ice. Replace

worn studs and skags to maintain proper balance and vehicle control.

WARNING

Loss of control can result in serious personal injury or death. Proper balance

of traction products on the skis and track must be maintained to obtain proper

vehicle control on hard-packed snow or ice. See your dealer for assistance.

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THE PERFECT FIT

Traction Products

Wear Strips

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

whenever track studding is used. See your dealer for more information.

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

studding chart for recommended traction accessories.

Components (viewed from rear of track)

1. Top of tunnel

2. Wear strip

3. Track

4. Wear strip mounting holes

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.

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THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile to help

make each ride more enjoyable.

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 ser-

vice.

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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

Recoil Rope

91, 94

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

47, 48, 86

Taillight/Brakelight/Headlight

Suspension Mounting Bolts

Skags (Wear Bars)

108

103

108

Ski Saddle and Spindle Bolts

Hood Straps/Latches

Seat Latches (if equipped)

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

62, 63

Tether Switch/Strap

N/A

49, 100

101

Track Alignment/Condition

Rail Slide Condition

Chaincase Oil Level

Injection Oil Level

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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

coule 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 machine is operated.

See page 62.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hydraulic 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 1/2I (1.3 cm).

A smaller distance indicates

1/2I (1.3 cm)

low brake fluid level or air in

the hydraulic system. Refer to

the brake bleeding information

on page 88 or see your dealer for service.

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

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

87.

WARNING

Continued use of “spongy” brakes may cause a complete loss of brakes,

which could result in serious injury or death. Always have the brakes serviced

at the first sign of sponginess.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Your snowmobile may have a

parking brake lever lock located

over the brake lever. Use the

brake lever lock only when you

want the machine to remain sta-

tionary; for example, when

parked on an incline for a period

of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

(if equipped)

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 brake light on the console 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 and release it. 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.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

WARNING

Ice and snow build-up may interfere with the steering of your machine, result-

ing 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.

n Track

WARNING

Always inspect the track for damage before using the vehicle. Operating the

snowmobile with a damaged track increases the possibility of track failure,

which could cause loss of control resulting in serious injury or death.

Use of traction products such as studs increases the possibility of track

damage and/or failure. Driving at high speeds for extended periods of

time with inadequate lubrication could severely damage track rods,

break track edges, and cause other track damage. Examples of inade-

quate 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 under

poor lubrication conditions voids the track warranty.

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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 Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the

seat latches are securely in place before every use of the snowmobile.

n Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the

knot securing the rope inside the handle is secure. If excessive wear is

found, see your Polaris dealer for replacement.

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

n Operating Area

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

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

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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 fuel valve on. See

page 57.

CHOKE POSITIONS

2. Turn the key to the ON

position.

OFF

3. Pull the engine stop switch

up to the RUN position.

1/2 CHOKE

4. If starting a cold engine,

flip the choke toggle to

FULL CHOKE. Do not use

the choke if starting a warm

engine.

FULL CHOKE

NOTE: Do not depress the throttle until the engine starts.

WARNING

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

snap back into the housing. Damage may result.

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

pull-rope starter while the engine is running.

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

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

6. If not equipped with electric start, grasp the recoil rope handle and

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

engine.

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

8. After the engine starts, flip the choke toggle to the OFF position. If

the engine slows or wants to stop, use intermittent choking to the

HALF CHOKE position.

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OPERATION

Engine Break-In

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

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

first tank of fuel with one pint of Polaris injection oil for each five gal-

lons of fuel. This, in addition to the lubrication supplied by the injection

system, will assure proper engine break-in.

CAUTION

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

close-fitted engine parts. Do not operate at full throttle or high speeds for

extended periods during the first three hours of use. Vary the throttle open-

ings and machine speeds to reduce friction on all close-fitting machined

parts, allowing them to break in slowly without damage.

Use of any lubricants other than those recommended by Polaris may cause

serious engine damage. We recommend the use of Polaris lubricants for your

vehicle.

Drive with extra caution during the break-in period. Perform regular checks

on fluid levels, lines, and all other important areas of the machine.

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OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 59.

CAUTION

Serious engine damage can occur without the proper lubrication. Check the

oil tank level often during the first tank of fuel. If the oil level doesn't go down,

contact your dealer immediately.

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES).

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

systems. Polaris recommends the use of VES II 2 Cycle Oil for this

engine. See page 113 for the part numbers of Polaris products.

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

system blockage, resulting in serious engine damage. Oils may also be

incompatible and the result could be sludge formation, filter blockage,

and reduced cold weather flow rates. All Polaris oils are compatible

with each other.

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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. Use a stable rear sup-

port.

WARNING

Use of traction products such as studs, ice growsers, etc. will increase the

possibility of track damage and/or failure. This could cause loss of control,

resulting in serious injury or death. Always inspect for track damage before

operating the snowmobile.

Follow these steps to ensure proper warm-up of the engine, drive train

and track.

1. Use an appropriate stand to securely

support the rear of the snowmobile at

the rear bumper. The track should be

about 4I (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 outdoor temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower

the machine to the ground.

5. Grasp the skis by their front loops and move them from side to side

to loosen snow and ice.

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OPERATION

Slide Rail and Track Cooling

CAUTION

Inadequate cooling and lubrication will lead to overheating of the slide rail

and track, resulting in premature wear and failure. Reduce speeds and fre-

quently drive into fresh snow to allow adequate cooling and polishing of the

slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or

roads.

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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.

• Turn the fuel valve off whenever the snowmobile is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm. Operate this vehicle only

outdoors or in well-ventilated areas.

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OPERATION

Fuel

Fuel Valve

Turn the fuel valve clockwise to

OFF to shut off the fuel supply.

Turn the valve counter-clockwise

to ON to turn the fuel supply on.

OFF

Fuel Recommendations

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

89 octane oxygenated pump gasoline. There's a great deal of variability

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

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

containing more than 10% ethanol (including E85).

CAUTION

Using fuels with a lower than recommended octane or operating with

obstructed fuel systems will result in serious and costly engine damage.

Always use the recommended fuels for your machine.

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OPERATION

Fuel

Fuel Reserve Capacity (Mechanical Gauge)

There are approximately two gallons of fuel left in the tank when the

mechanical fuel gauge reads RES.

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 113 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.

CAUTION

Prolonged exposure to petroleum based products may damage paint. Always

protect painted surfaces when handling fuel.

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OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.

Visually check for oil in the bottle. Add oil before further operation of

the snowmobile.

CAUTION

Operating the snowmobile without adequate engine lubrication can result in

serious engine damage. Always check the oil level when refueling. Add oil as

needed.

Low Oil Level

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

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

especially important when the machine is operated in mountainous ter-

rain.

Always check the oil level when refueling. Maintain the oil level above

the tank's low level line. When the oil reaches the low level mark, add

one U.S. quart of recommended oil. See page 54 for oil recommenda-

tions.

NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil

flow. See your Polaris dealer for recommended replacement

parts.

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OPERATION

Carburetion

Proper carburetor adjustment is critical. A lean mixture (too much air,

too little fuel) may result in piston burning, bearing failure, or complete

engine failure. A rich mixture (too much fuel, too little air) may foul

plugs and cause generally poor engine performance.

A lean mixture may be caused by things like fuel line restrictions, for-

eign matter in the carburetor or clogged fuel filters. A rich mixture may

be caused by snow build-up on the pre-filter in the air intake system.

Either condition may be caused by improper carburetor adjustment.

WARNING

Improper carburetor adjustments may result in operator safety hazards as

well as serious engine damage. Always have your Polaris dealer perform any

carburetor adjustments.

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OPERATION

Carburetion

Jetting Guidelines

Changes in altitude and temperature affect air density, which is the

amount of oxygen available for combustion. In low elevations and cold

temperatures, the air has more oxygen. In higher elevations and higher

temperatures, the air is less dense.

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

ambient temperatures from +5 to +25 degrees F. (-15 to -4 degrees C.).

Carburetors must be re-calibrated if the snowmobile is operated outside

this production temperature and/or altitude range. The main jet installed

in production is not correct for all altitudes and/or temperatures. See

page 83 for more information.

CAUTION

A main jet that's too small will cause a lean operating condition and may

cause serious engine damage. Jet the carburetors carefully for elevation and

temperature according to the jetting charts in your Owner's Manual Supple-

ment.

NOTE: It's the owner's responsibility to ensure that the correct jets are

installed in the machine for a geographical area. Be very care-

ful when jetting down in warm weather. As the weather turns

colder it will be necessary to re-jet upward to prevent engine

damage. When selecting the proper main jet always use the

lowest elevation and temperature that is likely to be encoun-

tered.

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OPERATION

n Engine 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 ON position to

allow restarting.

n Throttle Safety Switch

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

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

valves do not return to the normal closed position.

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in

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

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

immediately push down the engine stop switch. Do not start the engine again

until the malfunction has been corrected by your dealer.

Test the throttle safety switch

system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it

to idle.

3. Hold the throttle lever pin

stationary by exerting pres-

sure on the pivot pin in the direction shown in the illustration.

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

must shut down the engine.

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OPERATION

Throttle Lever

WARNING

An improperly functioning throttle lever may cause erratic machine behavior

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

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

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

1. Turn the ignition switch to OFF.

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

caused the safety switch to activate.

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

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

completely.

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

go through normal starting procedures.

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

Polaris dealer for service.

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

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

machine to an authorized Polaris dealer for service.

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

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

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

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

machine with the throttle safety switch disconnected. Return the

machine to an authorized Polaris dealer for service as soon as possible.

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OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. See page 62 for more information about the

engine stop switch and throttle safety switch.

THROTTLE

CONDITION

SYSTEM

Ignition Switch

WHAT IT DOES

Interrupts ignition circuit

Slows jackshaft

All

Brake

All

Choke

Floods engine

Half throttle or less

Engine Stop Switch

Throttle Safety Switch

Interrupts ignition circuit

All

Tether Switch (if available) Interrupts ignition circuit

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OPERATION

Reverse Operation

Electronic Reverse (PERCt)

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

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

tion setting as described on page 67. Always make sure the vehicle is

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

WARNING

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

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

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

speed.

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

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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.

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OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

3. Push the yellow reverse but-

ton (+) on the left-hand con-

trol for one second, then

release. The engine will auto-

matically reduce RPM and

start a reverse rotation. A

flashing reverse light on the

instrument panel will indicate

that the transmission is in

reverse.

4. Apply the throttle slowly to

make sure the transmission is

in reverse.

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

NOTE: If the engine stops running, the snowmobile will be in forward

gear when it's restarted.

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OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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.

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

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

instrument panel will shut off.

3. Apply the throttle slowly to make sure the transmission is in for-

ward.

Altitude Setting

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

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

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

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

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

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

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

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OPERATION

Daily Storage

At the end of each ride, park the snow-

mobile on a level surface and support it

at the rear with an appropriate track

stand. The track should be suspended

approximately 4I (10 cm) off the

ground. Remove the key and cover the

machine.

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OPERATION

Towing

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

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

vehicle if force is applied.

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

following warnings and understand the proper hitch functions.

WARNING

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

the rear of the snowmobile or other objects, resulting in serious injury or

death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a

rope. Only a stiff metal pole connecting the towed object and the tow hitch on

the snowmobile should be used. If passengers are to be towed on a 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.

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MAINTENANCE

Emission Control Information

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

repair the emission control devices or systems on your snowmobile.

Emission Control Label

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

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

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

Protection Agency regulations. The ECI label is permanently affixed to

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

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

You may remove the factory-installed emissions information hangtag,

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

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

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

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

qualified dealer for diagnostic service. Specifications and adjustments

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

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

be engaged during engine tune-ups.

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MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and

read the maintenance section of your owner's manual. You are responsi-

ble for ensuring that the specified maintenance is performed. Polaris

recommends that you contact an authorized Polaris dealer to perform

any service that may be necessary.

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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 130.

The recommended maintenance schedule on your snowmobile calls for

service and maintenance inspections at 150 miles (240 km), 500 miles

(800 km) and 1000 miles (1600 km). These inspections should be per-

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

mance and component life, continue maintenance checks at 1000 mile

(1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

of authorized warranty repairs, become the responsibility of the regis-

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

occur as a result of owner neglect in performing recommended regular

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

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

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

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

able performing these tasks yourself, contact an authorized Polaris

dealer for service.

CAUTION

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

exhaust system and engine have cooled before tipping the snowmobile on its

side for service or inspection.

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MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You

may need to increase frequency based on riding conditions. When

inspection reveals the need for replacement parts, always use genuine

Polaris parts, available from your Polaris dealer.

Item

See

Page

Frequency

1000 mi.

150 mi.

500 mi.

2000 mi.

Pre-

Season

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

CLUTCH

Clutch Alignment Offset

(without belt)

Drive Belt Condition

Clutches (disassemble)

Belt Tension

Clutch Sheaves

ENGINE/COOLING

Engine Mounts

Recoil Rope

Engine Mounting Plate

Engine Torque Stop

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

Spark Plug Condition

Exhaust Pipe

Exhaust Retaining

Springs

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

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

1000 mi.

150 mi.

500 mi.

2000 mi.

Pre-

Season

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

BRAKES

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads

Brake Disc

Parking Brakes

Brake System

Brake Fluid

47, 86

FUEL MANAGEMENT

Pilot Air Screws

Carburetor

(synchronize)

Idle RPM

Throttle Lever

Oil Pump Lever

(synchronize)

Throttle Cable

Choke Cable

Choke

Vent Lines

Fuel Lines

Oil Lines

Air Box

Drain and Water Traps

ELECTRICAL

Auxiliary Shut-Off

Switch

Throttle Safety Switch

Ignition Switch

Taillight

Brakelight

Headlight

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

1000 mi.

150 mi.

500 mi.

2000 mi.

Pre-

Season

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

CHASSIS

Ski Toe Alignment

Suspension Mounting

Bolts

Steering Fasteners

Rear Suspension Fas-

teners

Suspension Shock Oil

Cooling Fins and

Shroud

Drive Shaft Bearing

Jackshaft Bearings

Skags (Wear Bars)

110

103

Ski Saddle/Spindle

Bolts

Ski Pivots

Ski Spindle

Steering Arm(s)

Upper / Lower Steering

Post Support Bracket

Drive Chain Tension

Hood Latches

Battery Fluid Level

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

104

Rear Suspension Pivot

Shafts

Camber Alignment

Radius Rod Bushings

Handlebar Centering

Track Alignment

Track Tension

100

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

101

N/A

Gearcase Oil

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

C - Clean R - Replace L - Lubricate

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MAINTENANCE

Lubrication

Suspension and Steering

Lubricate the suspension and steering components with Polaris Pre-

mium All-Season Grease at 500 miles (800 km) and annually or every

1000 miles (1600 km) thereafter. A grease gun kit, complete with grease

and adaptors, is available to lubricate all fittings on Polaris snowmo-

biles. See page 113 for the part numbers of Polaris products.

The illustration shows the lubrication points of suspension and steering

components. Grease the left and right spindles. Raise the front end of

the machine to permit better grease entry into the spindle area.

• Lubricate both of the front ski pivots at the fittings as shown.

• Grease the driveshaft clutch side bearing.

• Use an aerosol lubricant on the steering post support bracket.

• Grease the steering post lower pivot.

• Grease the rear suspension pivot shafts (raise the rear of unit).

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MAINTENANCE

Lubrication

EDGE 136 Rear Suspension

Driveshaft Bearing

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.

Choke and Choke Cable

Lubricate the choke slide and cables

lightly with oil or grease. Before

turning the engine off, operate the

choke intermittently to draw mois-

ture out of the choke plunger area

and reduce the possibility of the

choke becoming frozen.

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MAINTENANCE

Lubrication

n Chaincase Oil

Check the chaincase oil level at the intervals outlined in the mainte-

nance charts beginning on page 72. Change the chaincase oil after the

first 500 miles (800 km), then every 1000 miles (1600 km) or season-

ally.

Maintain the oil level between the “safe” marks on the dipstick. Clean

the magnetic plug on the dipstick whenever checking or changing oil.

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See

page 113 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on

a level surface.

2. Remove the dipstick (1)

and view the oil level

on the dipstick.

3. Add the recommended

oil as needed. Do not

overfill.

4. Clean the magnetic

plug (2).

5. Reinstall the dipstick.

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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. Refer to your Owner's

Manual Supplement for the specific spark plug to be used in your

machine.

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. See your

Owner’s Manual Supplement.

• Use recommended spark plugs with the proper gap.

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

• Always carry spare spark plugs.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed up

and the vehicle has been driven at higher speeds. Immediately check the

spark plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective

gloves when removing a spark plug for inspection.

NOTE: Incorrect fuel mixture can often cause a spark plug to appear

too dark or too light in color. Before changing spark plug heat

ranges, be sure the correct main jet is installed in the carbure-

tor(s). Refer to the Owner's Manual Supplement or see your

dealer.

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MAINTENANCE

Spark Plugs

Normal Plug

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

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

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

NOTE: The tip should not be white. A white insulator tip indicates over-

heating, caused by use of an improper spark plug or incorrect

carburetor/throttle body adjustments.

Wet Fouled Plug

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

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

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

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

rect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation.

4. Torque the spark plug to specification. See page 79.

5. Verify that gap is within specification. See your Owner’s Manual

Supplement.

6. Reinstall the spark plug cap.

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MAINTENANCE

Intake Filters

CAUTION

Operating the snowmobile with the intake filters removed may cause carbu-

retor icing. The result will be poor fuel economy or carburetor malfunction.

Always reinstall the intake filters before operating the snowmobile.

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.

NOTE: These illustrations are general representations. Your model

may differ.

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MAINTENANCE

Fuel Filter/Fuel Lines

The fuel filter is located inside the fuel tank. This component requires

no maintenance.

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.

Oil Filter

The oil filter on your model is assembled into the oil sending unit

located in the bottom of the oil tank. This component requires no main-

tenance.

If service is performed to the oil injection system, trapped air must be

bled from the system. See your dealer for instructions, or have your

dealer perform this service.

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MAINTENANCE

Carburetor

The number stamped in the end of the main jet indicates the jet size. The

jet installed at the time of manufacture is not necessarily correct for your

elevation. It's your dealer's responsibility to make sure the correct main

jet is installed.

CAUTION

Operating the snowmobile with incorrect jetting can result in serious engine

damage. Have your Polaris dealer perform all carburetor adjustments to

ensure all adjustments are done correctly.

Carburetor Adjustments

The frequency at which the carburetors are synchronized or balanced is

important. Properly adjusted carburetors can greatly improve engine

performance, fuel economy, engine life, and reliability.

If you notice any of the following conditions, the carburetor may need

adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

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MAINTENANCE

Carburetor

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl water/sedi-

ment traps located at the bottom of each carburetor. The trap, consisting

of a hose with a plug, should be drained at least every 2000 miles (3200

km) and inspected for contamination.

WARNING

When draining the traps, fuel spillage will occur. Always work in a well venti-

lated area away from anything that may cause the fuel to ignite, such as open

flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline

warnings found on page 56.

1. Turn the fuel tank supply valve off.

Clamp

2. Position a container or shop towels to

catch the contaminated gasoline.

3. Slide the clamp away from the drain

plug and remove the drain plug from

the sediment tube.

4. Wipe residue from the plug and reinstall

it. Reposition and tighten the clamps.

Continue until all traps have been emp-

tied.

Drain

Plug

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MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000

miles (3200 km). To inspect, allow the engine and exhaust system to

cool completely. Open the hood and inspect the muffler and pipes for

cracks or damage. Check for weak or missing retaining springs or

damper/support grommets.

WARNING

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

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

running.

Drive Chain Tension

To obtain correct chain tension:

1. Rotate the driven clutch

counterclockwise to move all

chain slack to the tensioner

side. Lock the brake lever

lock, or have an assistant

hold the brake lever firmly.

Adjuster

Bolt

Jam

Nut

2. Loosen the adjuster bolt 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 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

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MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See

page 47.

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

ner than the backing plate (approximately 1/16I). A kit is available for

replacing brake pads. See your dealer.

WARNING

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

functioning brakes are vital to your safety. Be sure the brake pads do not

drag on the disc and that brake lever travel is not excessive.

Always replace brake pads when the brake pad material becomes thinner

than the backing plate (approximately 1/16I).

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance

develops, bring the machine to an authorized Polaris dealer for inspec-

tion and adjustment.

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material

(Replace when thickness is

less than 1/16I/1.5 mm).

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MAINTENANCE

Brakes

Brake Fluid

On some models, the brake fluid level can be seen through a plastic

sight glass in the brake reservoir. If the fluid is sufficient, the sight glass

will be black. If the sight glass is any color other than black, add brake

fluid.

On all other models, frequently check the reservoir to be sure it contains

the correct amount of fluid. To add fluid, remove the master cylinder

reservoir cover. Add the recommended brake fluid to bring the level up

to the top of the fluid level mark on the inside of the reservoir.

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

temperature brake fluid. See page 113 for the part numbers of Polaris

products.

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.

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MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.

Bleed the system before operating the snowmobile.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes,

which could cause an accident and lead to serious injury or death. Never

operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-

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

air entering the system through the reservoir vent.

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

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

marks or 1/4-5/16I (.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 87.

8. Reinstall the gasket and cover.

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MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following pro-

cedure.

1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed 2I (5.1 cm) below the mark placed on the

wall.

NOTE: Rider weight must be included on the seat.

5. Turn the adjustment nut (+), located inside the hood, just below the

headlamp opening. Turn the knob in or out as needed for proper

aim.

25 ft. (7.6 m)

Lamp Center Height

2I (5.1 cm)

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MAINTENANCE

Lights

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin

leaves a residue, causing a hot spot that will shorten the life of

the lamp. If fingers do touch the bulb, clean it with an alcohol-

moistened towel.

Headlight Bulb Replacement

1. Pinch the ends of the spring (1)

together and lift until it releases

from the spring retainer.

2. Lift the spring carefully around

the wire harness (2) and flip it to

the outside of the housing.

3. With the wire harness attached

to the bulb (3), withdraw the

bulb from the housing.

4. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

5. Hold the new bulb by its metal base and install it into the wire har-

ness.

6. Insert the bulb into the housing. Carefully flip the spring back into

the housing, placing it around the wire harness.

7. Squeeze the spring together until it's over the spring retainer and

release.

8. Verify headlight aim. See page 89.

Taillight/Brakelight Replacement

1. Remove the screws (1) securing the

taillight housing (2).

2. Remove and replace the bulb (3).

3. Reassemble all components.

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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

machine until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized

Polaris dealer. Any unauthorized modifications to clutches, such as adding or

removing weights, will void the warranty.

CAUTION

The bushings in the weights and rollers of Polaris clutches are made of a

material that may be damaged if lubricated. Do not lubricate clutch bushings.

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.

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 Belt Troubleshooting on page 118.

For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the

snowmobile.

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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.

2. Turn the ignition key off. Wait for the engine to stop completely.

3. Lock the parking brake (if equipped).

4. Open the hood.

5. Remove the clutch guard retain-

ing pin and open the clutch

guard.

6. Locate the L-wrench in the tool

kit and install it into the open

threaded hole in the outer sheave

of the clutch. Rotate the wrench

until the sheaves open far enough

to remove the belt.

7. Firmly grasp the belt midway

between the clutches and pull

upward and rearward to remove.

See illustration.

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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 rota-

tion by positioning the

identification numbers

so that you can read

them. If required, sepa-

rate the sheaves as

outlined in the belt removal procedures.

2. Turn the driven clutch moveable sheave clockwise while pushing

inward and forcing the belt down between the sheaves.

3. Hold the belt down between

the sheaves and roll the bot-

tom portion over the outer

clutch sheave. Work the belt

to the outer edge of the

sheave.

4. Rotate the L-wrench to

tighten the sheaves. Remove

the wrench and store in the

tool kit.

5. Close the clutch guard and

reinstall the retaining pin.

6. Close and secure the hood and release the parking brake.

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MAINTENANCE

Clutch System

n Drive Belt Deflection

Measure belt deflection with both

clutches at rest and in their full

neutral position.

Place a straight edge (1) on the

belt and apply downward pressure

while measuring at point 2. This

measurement should be 1 1/4

inches (3.2 cm).

Drive Belt Adjustment

Belt deflection can be adjusted without removing the clutch from the

jackshaft.

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch 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.

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MAINTENANCE

Clutch System

Torque Stop

If your snowmobile is equipped

with an engine torque stop, periodi-

cally check torque stop clearance.

.010-.030I

(.25-.75 mm)

With clutches in proper alignment,

the torque stop clearance should be

.010I-.030I (.25-.75 mm) from the

engine case.

Adjust if necessary, and lock the

jam nut.

Reverse Maintenance

If your snowmobile is equipped

with reverse, or if you have a

reverse kit installed, it's especially important to maintain track tension

as specified on page 98.

WARNING

Improper track tension can cause serious damage to the snowmobile, which

can result in loss of vehicle control and serious injury or death. Always main-

tain the track tension as specified.

Allow the engine to reach idle speed before attempting to shift into or

out of reverse.

CAUTION

Damage will occur to chaincase or transmission if shifting is attempted before

the machine has come to a complete stop. Make sure the snowmobile has

completely stopped and the engine has returned to idle speed before shifting

gears.

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MAINTENANCE

Chain Tension

Maintain the proper chain tension as outlined on page 85.

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your

Polaris dealer. His experienced and trained service technician will keep

your machine in peak operating condition.

Tool Kit

A tool kit is included with each machine for emergency and routine

maintenance. Always keep the tool kit with the snowmobile.

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MAINTENANCE

Track

Track Inspection

WARNING

Broken track rods can cause a rotating track to come off the machine, which

could cause serious injury or death. Never operate with a damaged track.

Never rotate a damaged track under power.

1. Using a hoist, safely lift and

support the rear of the snow-

mobile off the ground.

2. Rotate the track by hand to

check for damage.

3. Carefully examine the track

along the entire length of each

rod (+). Bend the track to

check for breakage.

4. Replace the track if any rod

damage is found.

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 peri-

ods on ice and other surfaces that have little or no snow for lubrication.

The slide rail needs snow for lubrication. Excessive wear indicates

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

in limited lubrication, resulting in excessive wear.

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

additional wheel kits are available. See your dealer for more

information.

NOTE: Track damage or failure caused by operation on ice or under

other poor lubrication conditions will void the track warranty.

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MAINTENANCE

Track

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 Tension

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

rect tension and alignment.

TRACK TENSION DATA CHART

Measurement

Location

Slack

Measurement

Suspension

Weight

EDGE 136

10 lbs. (4.54 kg)

16I ahead of

rear idler shaft

1 1/8I-1 3/8I

(2.9-3.5 cm)

NOTE: Tension adjustments should be made only after the track is

warmed up and limber.

1. Turn the engine off.

2. Lift the rear of the machine and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track

at the specified distance (see chart) ahead of the center of the rear

idler wheel.

NOTE: Measure at the point where the weight is hanging.

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MAINTENANCE

Track

Track Tension

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

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

98.

If the track needs adjustment:

5. Loosen the rear idler

Locknut

shaft bolts.

Adjusting

Screw

Slack

Measurement

Shaft Bolt

6. Loosen the locknuts.

7. Tighten or loosen the

track adjusting

screws to provide

equal adjustment on

both sides of the

track.

8. Repeat the measure-

ment on the other

16 (40 cm)

Track

side of the track.

NOTE: Check more fre-

quently when

the machine is

new.

10 lbs. (4.54 kg)

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

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

10. Check track alignment (see page 100) and adjust as necessary.

11. Tighten the locknuts.

12. Tighten the idler shaft bolts.

13. (n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

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MAINTENANCE

Track

n Track Alignment

Periodically check that the track is centered and running evenly on the

slide rails. Misalignment will cause excessive wear to the track and slide

rail.

1. Safely support the rear of the machine with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track

turns slowly at least five complete revolutions. Stop the engine and

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

3. Inspect track alignment by

looking through the track

window to make sure the

rails (+) are evenly spaced

on each side. If the track

runs to the left, loosen the

idler shaft bolts, then

loosen the left locknut and

tighten the left adjusting

bolt. If the track runs to the

right, loosen the idler shaft

bolts, then loosen the right

locknut and tighten the

right adjusting bolt.

4. After adjustments are com-

plete, tighten the locknuts

and torque idler shaft bolts

to 35 ft. lbs. (47.5 Nm).

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

100

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MAINTENANCE

Steering System

n Rail Slide Wear

For ease of inspection, all

Polaris rail slides have a

wear limit indicator groove

to indicate the minimum

permissible slide 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 per-

manent damage to the track

or rails.

Minimum

Thickness

Replace when

worn to top of

groove

Steering Inspection and Adjustment

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

tighten if necessary.

EDGE IFS

101

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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 1/8I to 1/4I (3-6 mm) greater

than the measurement at point Y.

NOTE: If the skis are misaligned, we recommend that your dealer cor-

rect the alignment, since camber adjustment may also be

affected.

EDGE IFS

10I

102

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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 chip-

ping is found.

Skag Replacement

1. Raise and support the front of the machine so the skis are approxi-

mately 6I (15.2 cm) from the ground.

2. Remove the attaching hardware and pry the skag downward.

3. Remove the rear end of the skag.

4. Remove the front end of the skag.

5. Reverse the steps to install a skag.

103

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MAINTENANCE

Battery

Battery Fluid

A poorly maintained battery will deteriorate rapidly. Check the battery

fluid level often. Maintain the fluid level between the upper and lower

level marks.

WARNING

Battery electrolyte is poisonous. It contains acid! Serious burns can result

from contact with the skin, eyes, or clothing. If contact occurs, seek immedi-

ate medical attention.

KEEP OUT OF REACH OF CHILDREN.

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Call physician immedi-

ately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, open flames, cigarettes,

etc. away. Ventilate when charging or using in closed space. Always shield

eyes when working near batteries.

Battery Connections

Keep battery terminals and connections free of corrosion. When clean-

ing is necessary, remove the corrosion with a stiff wire brush. Wash ter-

minals and connections with a solution of one tablespoon baking soda

and one cup water. Rinse well with tap water and dry with clean shop

towels. Coat the terminals with dielectric grease or petroleum jelly.

CAUTION

Tap water contains minerals that will damage a battery and shorten its life.

Use only distilled water to refill your battery. Never allow cleaning solution or

tap water to enter the battery.

104

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MAINTENANCE

Battery

Battery Removal

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.

1. Disconnect battery hold down straps.

2. Remove battery vent tube from battery.

3. Disconnect black (negative) battery cable first.

4. Disconnect red (positive) battery cable second.

5. Carefully lift the battery out of the snowmobile. Do not tip it side-

ways or spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon

baking soda and one cup water to prevent damage to the vehicle.

105

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MAINTENANCE

Battery

Battery Installation

WARNING

Batteries contain gases that can explode. If the battery vent tube is pinched

or kinked, battery gases could accumulate. Whenever removing or installing

the battery, disconnect the negative (black) cable first and reinstall the nega-

tive cable last to avoid the possibility of explosion.

Battery electrolyte contains acid. Avoid skin contact with electrolyte as

severe burns may result.

1. Place the battery in its holder. Attach the hold down strap.

2. Install the battery vent line. It must be free from obstructions and

securely installed. Route the vent line properly to prevent kinks and

to allow for proper drainage.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Verify that cables and vent hose are properly routed.

106

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MAINTENANCE

Battery

Battery Storage

When your snowmobile is placed in storage for one month or more:

• Remove the battery.

• Charge it to the proper level.

• Store it in a cool dry place.

• Check and/or charge monthly.

Before using the battery, take it to your dealer for testing and recharging.

Batteries may freeze if not fully charged, resulting in cell damage.

Charge condition

Will freeze at:

100%

75%

50%

25%

-75_ F(-59_ C)

-24_ F(-31_ C)

0_ F(-18_ C)

+13_ F(-11_ C)

+18_ F(-8_ C)

107

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MAINTENANCE

n Pre-Ride Suspension Inspection

Loose nuts and bolts can reduce your snowmobile's reliability and cause

needless repairs and down time. Before beginning any snowmobile trip,

a visual inspection will uncover potential problems. Check the follow-

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

n Check suspension mounting bolts for tightness.

n Check rear idler wheel bolts for tightness. See page 99.

n Check rear idler adjusting bolt locknuts for tightness.

n Check front torque arm limiter strap condition.

n Check rail slide condition.

n Check track tension. See page 98.

n Lubricate all rear suspension components. See page 76.

n Check ski runner/skag condition. See page 103.

n Check ski spindle bolts for tightness.

n Check tie rod end nuts for tightness.

108

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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 113 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 machine should be stored in a dry garage or shed, out of direct sun-

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

cause condensation to form and damage snowmobile components.

Controls and Linkage

Lubricate bushings, spindle shafts, tie rod ends and cables as outlined in

the Periodic Maintenance Table beginning on page 73.

109

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MAINTENANCE

Extended Storage

Bearings

Grease the drive shaft clutch side bearing 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. To prevent oxida-

tion on the clutch sheaves, lubricate the sheave faces of the drive and

driven clutches with a light coat of oil or Polaris Cable Lubricant.

NOTE: After storage, always use acetone or alcohol to remove the oil

before reinstalling the drive belt.

Do not lubricate other clutch components, except the driven clutch shaft

bushing as outlined in the Master Repair Manual. See your dealer.

Engine and Carburetor Protection

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

tion of rust and corrosion on precision engine parts during storage.

Whenever the machine is stored for a period of more than 60 days, the

engine must be fogged with fogging oil. Follow the engine fogging

instructions provided on the container.

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

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

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

Top off with fresh fuel.

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

drain plugs. See page 84.

NOTE: Jet restriction caused by improper storage can cause lean con-

ditions and very poor slow speed driving quality.

110

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MAINTENANCE

Extended Storage

Engine and Carburetor Protection

Using a fuel stabilizer and topping off the fuel tank eliminates the need

to drain the fuel system. If you prefer to drain the fuel tank, use the fol-

lowing procedure

1. Transfer unused fuel from the fuel tank to an approved fuel con-

tainer using a siphon pump. Do not re-use fuel after storage.

2. Securely support the front of the snowmobile with a jack stand so

the machine is elevated and the engine is tilted rearward.

3. Remove the spark plug(s).

4. Rotate the engine slowly, watching the piston until it's at bottom

dead center (BDC), the lowest position in the cylinder. On twin cyl-

inder models, the opposite piston will be up.

5. Pour approximately two ounces of Polaris injector oil into the spark

plug hole.

6. Wait one to two minutes and perform steps 3-5 on remaining cylin-

ders.

7. Replace the spark plugs and lower the machine to the floor.

111

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MAINTENANCE

Extended Storage

Electrical Connections

Separate electrical connector blocks and clean corrosive build-up from

connectors. Lubricate or pack connector blocks with dielectric grease

and re-connect.

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.

Battery

Always prepare and maintain the battery as outlined on page 107.

Track and Suspension

Moderate track tension should be maintained

during summer storage. The machine should be

supported off the ground to allow the track to

hang freely.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Turn the fuel valve off. See page 57.

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

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

suitable straps.

4. Remove the ignition key to prevent loss.

112

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

2870791

Fogging Oil (12 oz. Aerosol)

2871098

2871097

2871240

2871721

2871722

2872347

2874438

2874439

2874443

Premium 2-Cycle Engine Oil (qt.)

Premium 2-Cycle Engine Oil (gal.)

Premium 2-Cycle Engine Oil (2.5 gal.)

Premium Gold Synthetic 2-Cycle Engine Oil (qt.)

Premium Gold Synthetic 2-Cycle Engine Oil (gal.)

Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)

VES II Synthetic 2-Cycle Engine Oil (qt.)

VES II Synthetic 2-Cycle Engine Oil (gal.)

VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)

Chaincase Lubricants

2873105

2872951

Synthetic Chaincase Lubricant (qt.)

Synthetic Chaincase Lubricant (12 oz.)

Grease/Specialized Lubricants

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

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Dielectric Grease (Nyogelt)

2871312

2871322

2871423

2871329

Additives/Miscellaneous

2871326

2870652

2872189

2872893

2870505

2872889

2872890

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT 4 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

Isopropyl

Brake and Clutch Cleaner

Carb and Throttle Body Cleaner

113

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TROUBLESHOOTING

Engine Troubleshooting

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

see your dealer if technical problems arise.

Problem

Probable Cause Solution

Erratic engine oper- Drive clutch binding

ating RPM during

•

Disassemble drive clutch to inspect

shift weights for wear and free

operation. SEE YOUR DEALER.

Clean and polish stationary shaft

hub.

acceleration or load

variations

•

Driven clutch mal-

function

•

Replace ramp buttons and rollers.

SEE YOUR DEALER.

Inspect movable sheaves for exces-

sive bushing clearance and replace

if necessary. SEE YOUR

DEALER.

Harsh drive clutch

engagement

Drive belt worn or

too narrow

•

Replace the drive belt.

SEE YOUR DEALER.

Replace the drive belt.

Excessive belt/

sheave clearance

Drive belt turns over Wrong belt for appli-

cation

Clutch alignment out

of spec

Adjust alignment offset. SEE

YOUR DEALER.

Engine mount bro-

ken or loose

Inspect and adjust or replace. SEE

YOUR DEALER.

Machine fails to

move

Clutch jammed

Check for twisted belt, broken

spring, sticking weights, lubrica-

tion. SEE YOUR DEALER.

Track jammed

•

Foreign object may be caught or the

rail slide melted to the track clips

due to lack of lubrication.

•

Track may be iced up or frozen to

the ground.

Chaincase sprocket

or chain jammed or

broken

Chain is loose or broken or chain

tightener is loose. SEE YOUR

DEALER.

114

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive sys-

tem

Broken drive clutch

components

•

SEE YOUR DEALER.

Bearing failure/

chaincase, jackshaft,

or front drive shaft

•

SEE YOUR DEALER.

Drive belt surface

flat spots

•

Inspect and replace as needed.

Drive chain loose

•

Inspect and adjust (or replace).

SEE YOUR DEALER.

Drive chain worn,

sprocket teeth bro-

ken

Poor low RPM per-

formance

Worn drive belt

•

Inspect and replace as needed.

SEE YOUR DEALER.

Excessive belt/

sheave clearance

Loose torque stop

Sticky clutch

•

Inspect and adjust.

SEE YOUR DEALER.

Engine doesn't turn

Seized engine

SEE YOUR DEALER. Seizure is a

result of poor lubrication, inade-

quate fuel supply, broken parts or

improper cooling.

Hydrostatic lock

•

Fuel may have entered the crank-

case while the vehicle was standing

or being transported. SEE YOUR

DEALER to correct the cause.

Drain plug(s) are located on the

lower crankcase for emergency

draining.

Engine doesn't start

(electric start mod-

els)

Wire connections

Poor fuel

•

SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

•

Replace with fresh winter fuel.

SEE YOUR DEALER.

Not enough fuel get-

ting to engine

115

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Engine turns but fails Faulty ignition

to start

•

Install new spark plug(s). If engine

still fails to start, check for spark. If

there's no spark, SEE YOUR

DEALER.

No fuel to engine

•

Make sure the fuel valve is on.

Use the choke. See page 52.

Make sure fuel tank contains fuel.

Ice may be in fuel line, filter or

pump. Add isopropyl alcohol to

fuel system. On the standard

Polaris carburetor, the choke will

not function with the throttle

depressed. See second item under

Probable Cause" of Engine Contin-

ually Backfires".

Flooded engine (too

much choke used)

•

Hold throttle open, crank engine

several times (may be necessary to

change plug(s).

Poor engine com-

pression

Mixture is too lean. A main jet that

is too small will cause seizure

resulting in loss of power. This

indicates a major engine problem

that must be repaired before operat-

ing. SEE YOUR DEALER.

Engine lacks power

Fouled or defective

spark plug(s)

•

Replace the plug(s).

Fuel filter (loss of

high RPM power)

Check fuel filter flow. Disconnect

hose and drain 1/2 cup. Fuel flow

should be steady and encompass

the entire diameter of fuel line. If

not, replace filter.

Incorrect clutching

•

SEE YOUR DEALER.

Carburetor and fuel

pump

Engine continually

backfires

Faulty plug(s)

•

Change plug(s).

Carburetor / Fuel

System

Dirt or ice may be in the fuel sys-

tem (add deicer to non-ethanol fuel

at all times to prevent icing).

Incorrect throttle

freeplay or faulty

switch

•

SEE YOUR DEALER.

116

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TROUBLESHOOTING

EDGE 136 Suspension

Problem

Solution

Rear suspension bottoms

too easily

•

Increase torsion spring preload

Increase rear shock compression damping by turning

screw clockwise

•

Increase torsion spring wire diameter (see your dealer)

Rotate RRSS to a higher position. See page 39.

Rides too stiff in rear

•

Check for binding suspension shafts and grease all

pivot points

•

Decrease torsion spring preload adjustments

Decrease rear shock compression valving by turning

screw counterclockwise)

•

Check for proper track tension

Rotate RRSS to a lower position. See page 39.

Machine darts from side

to side

•

Make sure skis are aligned properly

Make sure spindles and all steering components are

free turning

•

Make sure skags are straight on skis

Check rail slide and replace if worn

Reduce ski pressure:

A) Increase front track spring preload

B) Reduce IFS spring preload

C) Reduce rear torsion spring preload

Front end pushes

Steering is heavy

•

Check for worn skags

Check for binding suspension shafts and grease all

pivot points

Increase IFS spring preload by adjusting cam or

threaded adjuster

Adjust RRSS to a higher position

•

Check ski alignment

Check skags and skis for damage

Reduce ski pressure:

A) Increase front track spring preload

B) Reduce IFS spring preload by adjusting cam

C) Reduce rear torsion spring preload

•

Make sure spindles and all steering components are

free turning (elevate machine to check)

Too much weight transfer

under acceleration

Rotate RRSS to a higher position. See page 39.

Not enough weight trans-

fer under acceleration

Move RRSS to the rearward upper hole on high posi-

tion. See page 39.

117

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TROUBLESHOOTING

Drive Belt Troubleshooting

Belt Wear/Burn Diagnosis

Solutions

Causes

Driving at low RPM

•

Drive at higher RPMs. Gear the machine down. Check

belt deflection.

Insufficient warm-up

Towing at low RPM

•

Warm the engine at least five minutes. Take the drive

belt off the machine in extremely cold weather and

warm it up. Break machine loose from the snow.

•

Do not tow in deep snow. Use fast, aggressive throttle

to engage clutch.

Riding with high RPM

and slow speed (8000

RPM/10 MPH)

Lower the gear ratio. Reduce RPM. Avoid riding in

high ambient temperatures. Check for snow ingestion.

Ice and snow build-up

•

Warm the engine at least five minutes. Take the drive

belt off the machine in extremely cold weather and

warm it up. Break machine loose from the snow.

between track and tunnel

Poor engine performance

Check for carburetor and choke synchronization,

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

or dirt in the fuel tank or fuel line.

Loading machines onto

trailers

Skis may gouge into trailers and prevent the drivetrain

from spinning properly. Use enough speed to drive the

machine completely onto the trailer. Push and pull it to

finish loading if necessary.

Clutch malfunction

•

Inspect clutch components. See your dealer.

Use fast, aggressive throttle to engage clutch.

Slow, easy clutch engage-

ment

118

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WARRANTY

Service and Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the Polaris warranty information con-

tained in this manual. Contact your Polaris dealer for replacement parts, service

or warranty. Your dealer receives frequent updates on changes, modifications

and tips on snowmobile maintenance, which may supersede information con-

tained in this manual. Your dealer is also familiar with Polaris policies and pro-

cedures and will be happy to assist you.

When contacting us about parts, service, or warranty, always provide the fol-

lowing information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

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

identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-763-417-8650

Canada: 1-204-925-7100

119

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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.

120

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WARRANTY

Limited Warranty

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-

ITED WARRANTY on all components of the Polaris snowmobile against defects in

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

replacement of defective parts that are covered by this warranty. The warranty begins on

the date of purchase. This warranty is transferable to another consumer, during the war-

ranty period, through a Polaris dealer.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and setup of your snowmobile is very important in ensuring

trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer

setup will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

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

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

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

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

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

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

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

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

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

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

are not compatible with the snowmobile.

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

repair or replacement of any defective materials, or components or products. THE REM-

EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-

ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL

OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF

EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-

GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-

sion or limitation of incidental or consequential damages or implied warranties, so the

above limitations or exclusions may not apply to you if inconsistent with controlling

state law.

121

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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.

122

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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.

123

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WARRANTY

Polaris Second Year Engine Service Contract

Second Year Engine Service Contract is standard on all eligible new and unused snow-

mobiles that were Snow Checked through an authorized Polaris dealer during the

March/April Snow Check promotion. The free Second Year Engine Service Contract is

honored by all authorized Polaris snowmobile dealers in North America and is transfer-

able 120 days after the original purchase date, free of charge, through any Polaris snow-

mobile dealer. Coverage on Snow Check units is automatic. Although you do not

receive a warranty card, your dealership should have printed a copy of the warranty reg-

istration form. This form is your proof of warranty.

Consumer Exclusions

•

Each repair visit after the first twelve months of standard warranty coverage is sub-

ject to a $50 deductible.

•

The free Second Year Engine Service Contract applies to the first 5,000 miles or two

(2) calendar years from date of purchase, whichever comes first. Tampering with the

odometer shall void all warranties/service contracts. No extensions to coverage under

this engine service contract can be given. Used snowmobiles are not eligible under

this program.

•

Snowmobiles used for commercial purposes or for racing are excluded from cover-

age.

124

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WARRANTY

Polaris Second Year Engine Service Contract

Coverage

Coverage for second year engine failures due to defects in materials and workmanship

will be determined by Polaris in its sole discretion. Coverage is automatic with no addi-

tional paperwork required. The free Second Year Engine Service Contract is subject to a

$50 deductible per visit. Regular, documented service maintenance visits are required to

validate this warranty.

A partial list of items excluded from coverage includes:

•

Damage due to accident, fire, explosion, theft, or other causes beyond Polaris' con-

trol.

•

Damage caused by the failure of other components of the snowmobile.

Failures caused by improper fuel or oil.

Piston seizures, unless caused by a defective engine component.

Failures caused due to improper adjustments.

Failure due to unauthorized service.

Failures due to lack of service as required in the owner's manual or Polaris updates.

This includes off-season storage as listed in the owner's manual.

•

Failure due to use of unauthorized parts or modifications.

Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,

and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and

exhaust manifolds excluding paint coverage.

•

Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring

and other electrical components are excluded from coverage.

Cooling system coverage is limited to the water pump assembly and components,

fan, fan bearings, temperature sensor, gasket and seals.

•

Non wear related throttle body parts are covered. The fuel pump is covered.

Clutches and related clutch parts, including but not limited to, the drive belt, are

excluded from coverage.

•

Electrical components are excluded from coverage.

Gearcases and transmissions are excluded from coverage.

125

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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.

126

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WARRANTY

Exported Vehicles

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer's authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

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

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance (see page 119).

127

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WARRANTY

Snowmobile Engine Emissions Limited Warranty

This snowmobile engine emissions limited warranty is in addition to the Polaris

standard limited warranty for snowmobiles.

Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-

certified snowmobile engine is designed, built and equipped so it conforms with U.S.

Environmental Protection Agency regulations applicable to snowmobile emissions.

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 a period of 200 hours of engine operation, 4000 kilometers (2485 miles) of

vehicle travel, or 30 calendar months from the date of purchase, 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 all

components whose failure increases the snowmobile engine's emissions. 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

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

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATE IN THIS WARRANTY. Some states do not allow limitations on how

long an implied warranty lasts so the above limitation may not apply if it is inconsistent

with the controlling state law.

128

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WARRANTY

Snowmobile Engine Emissions Limited Warranty

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

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

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

engine that has been structurally altered, or when the snowmobile 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

maintenance is strongly recommended, but is not necessary to keep the emissions-

related warranty valid.

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

trol devices or systems on your snowmobile. Polaris recommends that you contact an

authorized Polaris dealer to perform any service that may be necessary for your snow-

mobile. Polaris also recommends that you use only Pure Polaris parts. It is a potential

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

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

controls is prohibited by federal law.

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MAINTENANCE LOG

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

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

accurate log of maintenance and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

131

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

132

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 44

Air Box Warning . . . . . . . . . . . . . . . 22

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

Altitude Setting, Reverse. . . . . . . . . 67

Avalanches. . . . . . . . . . . . . . . . . . . . 14

Coupling, Suspension . . . . . . . . . 37-38

Customer Service. . . . . . . . . . . . . . . 119

Deicers. . . . . . . . . . . . . . . . . . . . . . . . 58

Disabled Operators . . . . . . . . . . . . . . 11

Drive Belt . . . . . . . . . . . . . . . . . . . . . 17

Drive Belt Adjustment. . . . . . . . . . . . 94

Drive Belt Condition . . . . . . . . . . . . . 91

Drive Belt Deflection. . . . . . . . . . . . . 94

Drive Belt Installation . . . . . . . . . . . . 93

Drive Belt Removal. . . . . . . . . . . . . . 92

Drive Chain Tension . . . . . . . . . . . . . 85

Driver Awareness . . . . . . . . . . . . . . . 13

Driveshaft Bearing Lubrication. . . . . 77

Driving Downhill. . . . . . . . . . . . . . . . 16

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 15

Driving Responsibly . . . . . . . . . . . . . 20

Backrest . . . . . . . . . . . . . . . . . . . . . . 28

Battery . . . . . . . . . . . . . . . . . . . 104-107

Battery Connections. . . . . . . . . . . . 104

Battery Fluid . . . . . . . . . . . . . . . . . 104

Battery Installation. . . . . . . . . . . . . 106

Battery Storage . . . . . . . . . . . 107, 112

Bearings. . . . . . . . . . . . . . . . . . . . . 110

Bleeding the Brake System . . . . . . . 88

Brake Components. . . . . . . . . . . . . . 86

Brake Fluid . . . . . . . . . . . . . . . . . . . 87

Brake Inspection . . . . . . . . . . . . . . . 86

Brake Inspection, Hydraulic . . . . . . 86

Brake Lever Travel, Hydraulic . . . . 47

Brake System Bleeding . . . . . . . . . . 88

Brakelight Replacement. . . . . . . . . . 90

Brakes . . . . . . . . . . . . . . . . . . 47, 86-88

Electrical Connections. . . . . . . . . . . 112

Emission Control Information. . . 70-71

Engine Break-In. . . . . . . . . . . . . . 53-54

Engine Emissions Warranty . . 128-129

Engine Protection . . . . . . . . . . 110-111

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

Engine Stop Switch . . . . . . . . . . . . . . 62

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

Exhaust System . . . . . . . . . . . . . . . . . 85

Carbide Skags . . . . . . . . . . . . . . . . . 42

Carburetion . . . . . . . . . . . . . . . . . 60-61

Carburetor . . . . . . . . . . . . . . . . . . 83-84

Carburetor Adjustments. . . . . . . . . . 83

Carburetor Protection. . . . . . . . 110-111

Cargo Overload . . . . . . . . . . . . . . . . 11

Chain Tension . . . . . . . . . . . . . . . . . 96

Chaincase Oil. . . . . . . . . . . . . . . . . . 78

Choke. . . . . . . . . . . . . . . . . . . . . . . . 52

Choke Cable Lubrication. . . . . . . . . 77

Choke Lubrication . . . . . . . . . . . . . . 77

Cleaning and Preservation. . . . . . . 109

Clutch Alignment Offset . . . . . . . . . 91

Clutch and Drive System. . . . . . . . 110

Clutch Center Distance . . . . . . . . . . 91

Clutch Cover Warning. . . . . . . . . . . 22

Clutch Guard . . . . . . . . . . . . . . . . . . 18

Clutch Safety . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . . . 91-95

Cold Weather Drive-Away . . . . . . . 18

Controls and Linkage. . . . . . . . . . . 109

Coupling, Front To Rear . . . . . . . . . 37

Coupling, Rear To Front . . . . . . . . . 38

Filters, Intake. . . . . . . . . . . . . . . . . . . 81

FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fuel . . . . . . . . . . . . . . . . . . . . . . . 56-58

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 82

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 82

Fuel Recommendations . . . . . . . . . . . 57

Fuel Reserve . . . . . . . . . . . . . . . . . . . 58

Fuel System Deicers . . . . . . . . . . . . . 58

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 57

Handlebar Adjustment. . . . . . . . . . . . 40

Headlight Adjustment . . . . . . . . . . . . 89

Headlight Bulb Replacement. . . . . . . 90

Hood Latches. . . . . . . . . . . . . . . . . . . 50

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INDEX

Ice and Snow Build-up . . . . . . . . . . . 15

IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

IFS Adjustments . . . . . . . . . . . . . . . . 29

IFS Components . . . . . . . . . . . . . . . . 29

Inadequate Snow Conditions . . . . . . 19

Intake Filters . . . . . . . . . . . . . . . . . . . 81

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

Parking Brake Lever Lock . . . . . . . . 48

Passenger Warning . . . . . . . . . . . . . . 23

Polaris Products . . . . . . . . . . . . . . . 113

Preload, Front Shock Spring. . . . . . . 31

Pre-Ride Checklist . . . . . . . . . . . . . . 45

Pre-Ride Suspension Inspection . . . 108

Rail Slide Wear. . . . . . . . . . . . . . . . 101

Recoil Rope . . . . . . . . . . . . . . . . . . . 50

Registration, Warranty . . . . . . . . . . 121

Reverse Maintenance . . . . . . . . . . . . 95

Reverse Operation . . . . . . . . . . . 65-67

Reverse Warning, Electronic . . . . . . 24

Reverse, Electronic. . . . . . . . . . . 65-67

Rider Capacity . . . . . . . . . . . . . . . . . 11

Riding Apparel . . . . . . . . . . . . . . . . . . 9

Riding Position . . . . . . . . . . . . . . . . . 10

RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 38

Jetting Guidelines . . . . . . . . . . . . . . . 61

Lever

Brake. . . . . . . . . . . . . . . . . . . . . 26

Brake, Excessive Travel . . . . . . 86

Brake, Hydraulic. . . . . . . . . . . . 47

Brake, Spongy. . . . . . . . . . . . . . 88

Throttle . . . . . . . . . . . . . . . . 46, 63

Lever Travel, Brake . . . . . . . . . . . . . 86

Lights . . . . . . . . . . . . . . . . . . . . . 89-90

Low Oil Indicator Light . . . . . . . . . . 59

Lubrication . . . . . . . . . . . . . . . . . 76-78

Safety Decals . . . . . . . . . . . . . . . 22-25

Safety Symbols . . . . . . . . . . . . . . . . . . 6

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Scissor Stop, Front Rear . . . . . . . . . . 37

Scissor Stop, Rear Rear . . . . . . . . . . 38

Shock Components . . . . . . . . . . . . . . 30

Shock, Rear, Indy Select. . . . . . . . . . 36

Signal Words . . . . . . . . . . . . . . . . . . . 6

Ski Alignment. . . . . . . . . . . . . . . . . 102

Ski Skags . . . . . . . . . . . . . . . . . . . . 103

Slide Rail and Track Cooling . . . . . . 56

Snow Conditions. . . . . . . . . . . . . . . . 19

Spark Plug Condition . . . . . . . . . . . . 79

Spark Plug Removal . . . . . . . . . . . . . 80

Spark Plugs . . . . . . . . . . . . . . . . . 79-80

Speed. . . . . . . . . . . . . . . . . . . . . . . . . 12

Spring Preload, Front Shock. . . . . . . 31

Spring Preload, Rear. . . . . . . . . . . . . 34

Springs, Front . . . . . . . . . . . . . . . . . . 31

Starting the Engine . . . . . . . . . . . 52-53

Maintenance . . . . . . . . . . . . . . . . . . . 18

Maintenance Interval Table . . . . 73-75

Maintenance Log . . . . . . . . . . 130-133

Maintenance Program. . . . . . . . . . . . 72

Maneuverability . . . . . . . . . . . . . . . . 18

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

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 82

Oil Injection System . . . . . . . . . . . . . 54

Oil Level . . . . . . . . . . . . . . . . . . . . . . 59

Oil Recommendations. . . . . . . . . . . . 54

Operation Warning . . . . . . . . . . . . . . 25

Operator Safety. . . . . . . . . . . . . . . 6-21

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INDEX

Steering Inspection/Adjustment. . . 101

Steering Lubrication . . . . . . . . . . . . 76

Steering System . . . . . . . . . 49, 101-103

Stopping, Emergency. . . . . . . . . . . . 64

Storage, Daily . . . . . . . . . . . . . . . . . 68

Storage, Extended . . . . . . . . . . 109-112

Studs . . . . . . . . . . . . . . . . . . . . . . . . 41

Survival Preparation . . . . . . . . . . . . 10

Suspension Adjustments

Torsion Springs . . . . . . . . . . . . . . . . . 37

Towing. . . . . . . . . . . . . . . . . . . . . . . . 69

Track

Alignment . . . . . . . . . . . . . . . . 100

Care for Storage. . . . . . . . . . . . 112

Cooling . . . . . . . . . . . . . . . . . . . 56

Damage . . . . . . . . . . . . . . . . . . . 49

Inspection. . . . . . . . . . . . . . . . . . 97

Lubrication. . . . . . . . . . . . . . . . . 97

Safety. . . . . . . . . . . . . . . . . . . . . . 8

Tension . . . . . . . . . . . . . . . . 33, 98

Warm-Up. . . . . . . . . . . . . . . . . . 55

Warning . . . . . . . . . . . . . . . . . . . 23

Traction Products. . . . . . . . . . . . . 41-43

Transporting the Snowmobile . . . . . 112

Trap, Carburetor . . . . . . . . . . . . . . . . 84

Troubleshooting

EDGE 136 . . . . . . . . . . . . . . 34-39

Front. . . . . . . . . . . . . . . . . . . 29-31

Rear . . . . . . . . . . . . . . . . . . . 32-33

Suspension Coupling . . . . . . . . . . 37-38

Suspension Inspection, Pre-Ride . . 108

Suspension Lubrication . . . . . . . . 76-77

Suspension Performance Tips . . . . . 33

Switches

Drive Belt . . . . . . . . . . . . . . . . 118

Engine . . . . . . . . . . . . . . . 114-116

Suspension, EDGE 136 . . . . . . 117

Tune-Up. . . . . . . . . . . . . . . . . . . . . . . 96

Engine Stop . . . . . . . . . 26, 51, 62

Handwarmer . . . . . . . . . . . . . . 26

Headlight Dimmer . . . . . . . . . . 26

Ignition. . . . . . . . . . . . . . . . 26, 51

Throttle Safety . . . . . . . . . . 46, 62

Thumbwarmer . . . . . . . . . . . . . 26

Vehicle Identification Numbers. . . . . . 4

Taillight/Brakelight Replacement . . 90

Tension, Rear Spring . . . . . . . . . . . . 35

Throttle Cable Lubrication . . . . . . . 77

Throttle Lever . . . . . . . . . . . . . . 46, 63

Throttle Safety Switch. . . . . . . . 46, 62

Tool Kit . . . . . . . . . . . . . . . . . . . . . . 96

Torque Stop . . . . . . . . . . . . . . . . . . . 95

Warranty, Engine Emissions . . 128-129

Water Pump Belt . . . . . . . . . . . . . . . . 81

Water/Sediment Trap Service . . . . . . 84

Wear Strips . . . . . . . . . . . . . . . . . . . . 43

Weight Transfer. . . . . . . . . . . . . . . . . 39

Windchill . . . . . . . . . . . . . . . . . . . . . . 21

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