Polaris Offroad Vehicle Trail RMK User Manual

Pantone 426C

Trail RMK

Snowmobile Owner's Manual

for Maintenance and Safety

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WARNING

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

this manual and on all product labels.

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

WARNING

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

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

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WELCOME

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

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the Polaris Service Manual and should be

performed only by a Factory Certified Master Service Dealer (MSD)

Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser-

vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces-

sories, available through our online store at www.purepolaris.com. Have

your accessories and clothing delivered right to your door!

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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.

2010 Trail RMK Owner’s Manual

P/N 9922282

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

This section contains helpful information for owners and drivers and

illustrates the location of important identification numbers that should

be recorded in the owner’s manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

This section describes safe vehicle operation and identifies warning

decals and their locations.

Features and Controls. . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 43

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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

bile’s regular maintenance.

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 109

Suspension Troubleshooting . . . . . . . . . . . . 110

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 111

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 124

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

future owners of the vehicle.

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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INTRODUCTION

Important Notes for Owners and Drivers

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

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

sold.

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.

Some of the illustrations and photos used in this manual are general rep-

resentations. Your model may differ.

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INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam-

paign. We encourage state and provincial governments across the snow-

belt to adopt rigorous safety training programs that encourage protection

of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

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

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

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards.

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

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

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

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

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

by operating your snowmobile safely and responsibly.

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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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: ____________________________________________________________

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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, indicates the potential

for serious injury.

WARNING

A WARNING indicates a potential hazard that may result in serious injury or

death.

CAUTION

A CAUTION indicates a potential hazard that may result in minor injury.

NOTICE

A NOTICE indicates a situation that may result in damage to the vehicle.

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SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 65

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. They will reduce your alertness

and slow your reaction time. In most states and provinces, it’s prohibited by law

to drive while intoxicated or under the influence of drugs.

Polaris produces high performance snowmobiles capable of traveling at high

speeds. Extra caution must be observed to ensure operator safety. Make sure

your snowmobile is in excellent operating condition at all times. We strongly rec-

ommend that the operator 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 opera-

tion with any modifications, especially those that increase speed or power. DO

NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynami-

cally unstable at speeds higher than those for which it is designed. Loss of con-

trol 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

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

• Tool Kit

• Extra Oil

• Fuel Deicer

Riding Position

Operating a snowmobile requires skill and balance for proper control.

Rider positions may vary with experience; but under many conditions,

the proper position is to be seated with both feet on the running boards

and both hands on the handlebar grips for proper throttle, brake and

steering control.

WARNING! Improper riding position may reduce control and could result in

serious injury or death. Always ride in a position that allows for control of your

vehicle.

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SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be

comfortable when riding. Be

aware of the weather forecast,

especially the windchill, and dress

accordingly. See the chart on page

22.

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

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.

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.

Excessive Speed

Always observe all state and local laws governing snowmobile opera-

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

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

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

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

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

two seconds.

Traveling at night requires extra caution. Check headlight and taillight

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

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

nated by the headlight.

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.

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SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,

posts, or other obstacles. Be especially

alert if you’re snowmobiling after dark.

Always be on the alert for wire fences.

Single strands are especially dangerous,

since there may be a great distance

between posts. Guy wires on utility poles

are also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways.

The noise of your machine will drown out

the sound of approaching vehicles. Look

ahead, behind, and to both sides before

turning or crossing railroad tracks or high-

ways. Steep embankments may also hide

your view. Always leave yourself a way

out.

R R

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

thickness. Always check with local residents or authorities for general

information on conditions when traveling on lakes and streams that are

strange to you. Before riding your machine on a frozen body of water,

be sure the ice is thick enough to support the machine and its operator,

as well as the force created by a moving vehicle. You may drown if you

and the snowmobile break through the ice.

When teaching inexperienced operators to ride, set up a predetermined

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

snowmobile before allowing them to make longer trips. Teach them

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

safety courses sponsored by local or state organizations.

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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

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, check for ice and snow build-up that may be obstructing

the steering linkage. Snow screens and bib kits are available through

your dealer to help reduce snow and ice build-up.

WARNING! Ice and snow build-up may interfere with the steering of your

machine, resulting in serious injury or death. Keep the underhood area free of

snow and ice.

Driving on Slippery Surfaces

WARNING! Driving on ice or hard-packed snow reduces steering and braking

control, which may result in serious injury or death. Slow down and use caution.

If driving on ice or other slippery surfaces is unavoidable, use extreme

caution and operate at speeds no faster than a walk. Never attempt an

abrupt change of direction. The chance of “spin-out” increases under

these conditions.

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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.

Operating in hilly terrain requires extreme caution to maintain balance

and avoid roll-over. If climbing a hill is unavoidable, keep all your

weight low and forward.

If you must cross the face of a slope, keep your weight on the uphill side

of the machine to maintain proper balance and avoid possible roll-over.

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

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

other side of the hill.

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

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

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

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

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

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

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

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SAFETY

Operator Safety

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.

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 guard by removing it. It’s pro-

vided for your safety.

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed

by your dealer. Operation of the engine with the belt removed may result

in personal injury or damage to the engine.

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SAFETY

Operator Safety

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

Damage to the engine may occur if the intake silencer or filter are

removed.

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a

complex mechanism that rotates at high speeds. Each clutch is dynami-

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

sion balancing and create an unstable condition.

Cold Weather Drive-Away

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

cially overnight, always make sure the skis and track are loosened from

ice and snow before attempting to drive. Apply the throttle with enough

authority to put the machine into motion, but always operate within

safety limits. See Starting the Engine on page 49.

Maneuverability

Control and maneuverability comes not only through the steering and

skis, maximum control is achieved by shifting of body weight. Maneu-

verability will change for lighter operators or machines designed to

carry a load.

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SAFETY

Operator Safety

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension

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

cover is a requirement for operation of your machine.

NOTICE: Driving in too little snow will result in excessive wear and damage to

the slide rail, track and/or engine. Do not drive for prolonged periods

on blacktop, gravel, or ice. If frequently operating in low cooling condi-

tions, see your dealer for an optional wheel kit that will reduce the

wear from overheating.

Operating in Deep Snow

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.

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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.

WIND CHILL CHART (°F)

Wind

Speed

Actual Thermometer Reading (_F)

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

Equivalent Temperature (_F)

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

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

40 35 30 25 20 15 10

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

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

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

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

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

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

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

29 23 16

28 22 15

28 21 14

27 20 13

26 19 12

25 18 11

25 17 10

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

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

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

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

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

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

WIND CHILL CHART (°C)

Wind

Speed

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

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 this guard open.

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.

Passenger Warning

Your Polaris snowmobile is

designed for a single rider only.

A decal on the console indicates

single rider operation:

WARNING

This vehicle is designed for

operator only.

NO PASSENGER.

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SAFETY

Safety Decals and Locations

Track/Seat Warning

The track/seat 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 may result in

severe injury or death.

Reverse Warning

Polaris snowmobiles equipped with

electric reverse and will have this

decal on the console:

WARNING

Reverse operation, even at low

speeds, can cause loss of control

resulting in serious injury or

death. To avoid loss of control,

always:

• Look behind before and while

backing up.

• Avoid sharp turns.

• Shift to or from reverse only

when stopped.

• Apply throttle slowly.

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

If electric reverse:

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

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

• Push button again to return to forward.

• 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

An operation warning decal is present on the console of all Polaris

snowmobiles:

WARNING

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

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

tact a Polaris dealer for a replacement.

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

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

caution when operating in unfamiliar terrain.

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

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

avoid unexpected obstacles, or to stop safely.

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

cle.

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

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

pull the brake lever to stop.

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

clothing while operating this vehicle.

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

requirements.

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

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

passenger reduces your ability to control the vehicle.

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

steering and braking ability are greatly reduced. Reduce speed and

allow extra space to turn or stop.

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

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

Owner’s Manual for proper use of traction products.

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

of braking ability.

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

brake engaged for more than five minutes.

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

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

tion to control the vehicle.

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

refueling.

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FEATURES AND CONTROLS

1. Fuel Filler Cap (may include a fuel gauge)

2. Ignition Switch

3. Brake Lever

4. Speedometer (may include indicator/warning lights)

5. Reverse Indicator

6. Mountain Bar (accessory)

7. Engine Stop Switch (see page 58)

8. Throttle Control

9. Choke

10. Recoil Starter Handle

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FEATURES AND CONTROLS

Some Polaris snowmobiles are equipped with special features. Controls

for these features are illustrated on this page. Not all models come with

these features. See your Owner’s Manual Supplement.

Tip: Accessories are available from your Polaris dealer.

1. Headlight Dimmer

Switch

2. Parking Brake

Lock

3. Handlebar Grip

Warmer Switch

4. Thumbwarmer

Switch

5. Electronic Reverse

Button

Fuel Valve

The fuel valve is located under the

hood. Turn the fuel valve off when-

ever the snowmobile is stored or

parked.

1. Turn the valve clockwise to

turn off the fuel supply.

2. Turn the valve counter-clock-

wise to turn on the fuel supply.

OFF

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FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Operator Seat

6. Storage Compartment

7. Taillights

8. Snow Flap

9. Track

10. Suspension

11. Trailing Arm

12. Nosepan

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

14. Skis

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THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and re-

grease all suspension parts 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 under

the same conditions after each adjustment (trail and snow conditions,

vehicle speed, riding position, etc.) until the best ride is achieved.

Adjustments should be made to one area at a time in order to properly

evaluate the change.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

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THE PERFECT FIT

Front Suspension Adjustments

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Always verify ski alignment before

making adjustments to the IFS. See page 98 to check alignment. Do not attempt

to change the ski alignment or camber adjustment. See your Polaris dealer.

The tension at which the shock coil spring is set is called spring preload.

For the best ride, the spring preload should be set as low as possible to

use the full travel of the ski shock, with occasional light bottoming. To

determine if your machine is using full travel of the ski shock, push the

jounce bumper down as far as it will go on the shock rod and test ride

the machine. The bumper will move up on the rod in direct relation to

the amount of travel. If the shock travel is full, the bumper will be seated

at the top of the shock.

Shock Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Preload

Adjuster Nut

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THE PERFECT FIT

Front Suspension Adjustments

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

Front Suspension Adjustments

Shock Spring Preload

Increasing spring preload will

increase ski-to-ground pressure.

Decreasing spring preload will

decrease ski-to-ground pressure.

When adjusting, be sure the springs

on both the left and right sides of the

machine are at the same adjustment.

To increase front shock spring pre-

load, 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 han-

dling of the snowmobile and the per-

formance of the suspension. Never

exceed one inch of preload beyond

the factory settings, and ensure that

both sides are adjusted the same.

When decreasing preload, make sure

High

Preload

Low

Preload

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.

Tip: Some models do not have shocks with thread adjustable spring preload.

See your dealer for more information.

NOTICE: 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.

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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 condi-

tions. However, all suspension designs and adjustments involve a com-

promise, or trade-off. For example, a suspension set up for snow-cross

racing would provide a very stiff ride on the trail. A suspension set up

for trail riding would bottom out harshly on a snow-cross course.

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.

Suspension Performance Tips

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

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

little experimentation, each rider can find a preferred set-up. These

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

greatly affect the ride.

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

worn rail slide. It can also improve top speed.

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

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

are available from your dealer.

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

dealer for assistance.

Tip: Keep the suspension pivot points lubricated. This will reduce moisture and

rust build-up and ensure proper function of the suspension components.

Grease rear suspension pivots before adjusting the rear suspension. See

page 71.

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 94.

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THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the EDGE RMK rear suspension torsion spring preload, mea-

sure the distance between the ground and rear bumper (see illustration).

This measurement should be taken with no rider and the rear suspension

at full extension. This is measurement X.

Take the first measurement with no rider and with the rear suspension at

full extension.

Tip: The rear bumper may need to be lifted upward slightly to fully extend the

rear suspension.

Next, have the rider drop down hard on the seat and bounce up and

down several times, collapsing the rear suspension. With the rider

seated, measure the distance between the ground and the rear bumper at

the exact location used for measurement X. This is measurement Y.

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THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method))

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 this 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

Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion

spring preload, 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.

Soft/Low Tension

(Long end to front)

Medium Tension

(Short end up)

The following informa-

tion 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.

High/Firm Tension

(Long end up)

Optional Torsion Springs

Track

Soft

Standard

Firm

136

Not applicable

7041627-067 7041628-067 7041629-067 7041630-067

.347 77

.359 77

Limiter Strap Position

The following information is pro-

vided only as a guideline to be

used for initial suspension set-up.

Your set-up may vary based on

your desired riding style.

High

Low

High: Limiter strap in high posi-

tion increases ski pressure

Low: Limiter strap in low position

decreases ski pressure

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THE PERFECT FIT

Rear Suspension Adjustments

Shock Compression Damping

Your snowmobile is equipped with the Indy Select rear shock, which

allows for adjustments to the compression valving.

1. Locate the adjustment screw near the base of the shock.

2. Adjust the screw 1/2 turn clockwise to increase compression valv-

ing and stiffen the ride. Test ride the snowmobile before making

further adjustments.

Tip: An excessive adjustment can result in damage to the shock. When adjust-

ing these shocks, we recommend that you turn the screw only 1/2 turn at a

time, then test ride.

3. Adjust the screw 1/2 turn counterclockwise to reduce compression

and soften the ride.

There are approximately three full turns of adjustment available. If bot-

toming continues after the screw has been turned fully clockwise, the

torsion spring should be adjusted (see page 36). Return the screw to its

original starting position after the torsion spring has been tightened.

Adjustment Screw

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THE PERFECT FIT

Handlebar Adjustments

Standard Handlebar

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). If necessary, pry the

blocks apart with a screw-

driver.

3. Adjust the handlebar to the

desired angle. Be sure the

Nuts

handlebar, brake lever and

throttle lever operate

smoothly and do not hit the

gas tank, windshield or any

other part of the machine

when the handlebar is turned

fully to the left or right.

4. Torque the 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

Accessories

Polaris offers a wide range of accessories for your snowmobile. From

map light to electric start, Polaris has the accessories that will help make

each ride more enjoyable. See your dealer for a list of accessories.

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

• Personal injury to self or others

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

clutches, fuel systems, and exhaust systems.

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

parts. Please see your Polaris dealer for service.

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THE PERFECT FIT

Traction Products

Another way to tailor your machine is to install traction products. See

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

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

advice and assistance.

NOTICE: Installing studs on models without wear strips will result in damage to

the cooler or tunnel. Always ensure that wear strips are installed

before installing studs. See your dealer for more details.

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

in your area pertaining to the use of traction products.

Track studding will enhance braking control on hard-packed snow or

ice, but extreme caution is still required on such surfaces. Steering abil-

ity may be reduced on hard-packed snow or ice.

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.

NOTICE: Use of studs longer than the recommended length on machines

equipped with coolers will result in damage to the cooler or tunnel.

Always use the recommended length studs.

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THE PERFECT FIT

Traction Products

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

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

with roads and other bare terrain. The addition of carbide skags is rec-

ommended with studded tracks to help maintain proper vehicle steering

and control. Similarly, if your machine is equipped with carbide skags

or if you’re adding them, it may be necessary to add track studs to main-

tain proper vehicle control. Proper balance must be maintained between

the number of studs and the length of the carbide on skags. The more

studs used, the longer the carbide on the skags should be. See your

dealer’s track studding chart for recommended studding and skags.

n 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.

See page 99.

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 for more information.

NOTICE: Aggressive studding patterns may require that you grind protruding

stud bolts flush to prevent idler wheel damage. Maintain track tension

on studded tracks on the tight side of the spec to prevent heat

exchanger damage. Center of stud must be at least 1 1/8 inches (2.86

cm) from the outside edge of the track.

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.

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THE PERFECT FIT

Traction Products

Wear Strips

To avoid excessive tunnel or cooler damage, 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.

NOTICE: Never add shims to the wear strip. Track damage will result due to

lack of clearance between upper carrier wheels and track.

Components as viewed from the rear of the track:

1. Top of tunnel

2. Wear strip

3. Track

4. Wear strip mounting holes

NOTICE: 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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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

87, 90

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

45, 46, 81

Taillight/Brakelight/Headlight

Suspension Mounting Bolts

Skags (Wear Bars)

100

41, 99

100

Ski Saddle and Spindle Bolts

Hood Straps/Latches

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

44, 58, 59

95, 100

N/A

Tether Switch/Strap

Track Alignment/Condition

Front Torque Arm Limiter Strap Condition

Rail Slide Condition

47, 96

100

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 could result in serious injury or death. Never start the engine

without checking 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. See page 59.

n Throttle Safety Switch

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

See page 58.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

n Brakes

Properly functioning brakes are critical to your safety. Always check the

following items to assure proper operation before starting the engine.

Brake Lever Travel

Squeeze the brake lever. It

should move no closer to the

handgrip than 1/2 inch (1.3

cm). A smaller distance indi-

cates low brake fluid level or

air in the hydraulic system.

See pages 82-83 or see your

dealer for service.

1/2 inch (1.3 cm)

Lever Feel

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

level and condition. Also check for the presence of air in the fluid sys-

tem. See pages 82-83 or see your dealer for service.

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

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

serviced at the first sign of sponginess.

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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

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.

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

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

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

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

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

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

Lock Release

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

to the 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, resulting in serious injury or death. Keep the underhood area free of

snow and ice.

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

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

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

the steering linkage. Make sure all greasable components are properly

lubricated.

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.

Track damage or failure caused by operation on ice or under poor lubri-

cation conditions voids the track warranty.

n Hood Latches

The hood of the snowmobile protects the operator from moving parts as

well as aiding in sound emission control and other functions. Under no

circumstances should your snowmobile be operated with the hood open

or removed. Always ensure that the hood straps are in good condition

and that the latches are securely in place before operating the snowmo-

bile.

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 Lighting

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

Replace burned out lamps before operating.

n Mirrors (if equipped)

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

n Operating Area

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

make sure bystanders are a safe distance from the machine.

n Ignition Switch

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

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OPERATION

Starting the Engine

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

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

engage the starter when the engine is running.

1. Turn the fuel valve on. See

CHOKE POSITIONS

page 27.

2. Turn the key to the ON

OFF

position.

3. Pull the engine stop switch

up to the RUN position.

1/2 CHOKE

4. If starting a cold engine,

flip the choke toggle to

FULL CHOKE. Do not

use the choke if starting a

warm engine.

FULL CHOKE

CAUTION! Do not depress the throttle until the engine starts.

CAUTION! 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.

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

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

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

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

engine.

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

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

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

HALF CHOKE position.

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OPERATION

Engine Break-In

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

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

first tank of gasoline with one pint of Polaris injection oil for each five

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

tion system, will assure proper engine break-in.

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

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

speeds for extended periods during the first three hours of use. Vary

the throttle openings and machine speeds to reduce friction on all

close-fitting machined parts, allowing them to break in slowly without

damage.

Use of any lubricants other than those recommended by Polaris may

cause serious engine damage. We recommend the use of Polaris

lubricants for your vehicle.

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

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

machine.

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OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 55.

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

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

level doesn’t go down, contact your dealer immediately.

Oil Recommendations

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

systems. Polaris recommends the use of Premium 2-Cycle Oil for this

engine. See page 109 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! Use of traction products such as studs, ice growsers, etc. will

increase the possibility of track damage and/or failure. This could cause loss of

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

before operating the snowmobile.

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

and track.

1. Use an appropriate stand to securely

support the rear of the snowmobile at the

rear bumper. The track should be

approximately 4 inches (10 cm) off the

ground.

WARNING! A loose track or flying debris could

cause serious personal injury or death. Stand

clear of the front of the machine and the moving

track. Never hold the snowmobile up or stand

behind it while warming up the track. Do not use

excessive throttle during warm-up or when the track is free-hanging. Be sure the

rear support is stable.

2. Start the engine and allow it to warm up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several

revolutions.

Tip: It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

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

the machine to the ground.

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

This will loosen frozen snow from the ski bottoms, allowing the

machine to move forward more easily.

6. The engine, drive system and track are now properly warmed up

and the machine may be driven following normal safety practices.

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OPERATION

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

rail and track, resulting in premature wear and failure. Reduce speeds

and frequently drive into fresh snow to allow adequate cooling and

polishing of the slide rail and track surfaces. Avoid operating on ice,

hard-packed surfaces or roads.

Fuel

WARNING! Gasoline is highly flammable and explosive under certain

conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

eling is performed or where gasoline is stored.

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

and water and change clothing.

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

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

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

Exhaust

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 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, so we encourage the

use of premium fuel when possible. Do not use lower than 87 octane

fuel. Do not use fuel containing more than 10% ethanol (including E85).

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

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

age. Always use the recommended fuels for your machine.

Fuel 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 milliliters per liter) of gasoline to prevent engine damage resulting

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

additives containing methanol. See page 109 for the part numbers of

Polaris products.

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

ers or water absorbing additives are not required and should not be used.

NOTICE: 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. If oil is not visible, continued opera-

tion may cause serious engine damage. Add oil before further operation

of the snowmobile. See page 51 for oil recommendations.

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. When the oil reaches the low

level mark, add one quart (.9 l) of recommended oil to the tank. See

page 51 for oil recommendations.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

eling. Add oil as needed.

The Polaris oil cap on the oil bottle may be 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. Always have your Polaris

dealer perform any carburetor adjustments.

A lean mixture (too much air, too little fuel) may result in piston burn-

ing, bearing failure, or complete engine failure. A rich mixture (too

much fuel, too little air) may foul plugs and cause generally poor engine

performance.

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

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

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

Either condition may be caused by improper carburetor adjustment.

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OPERATION

Carburetion

Jetting Guidelines

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

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

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

temperatures, the air is less dense.

RMK carburetors are preset to operate at altitudes of 6000-8000 feet

(1800-2400 m) above sea level (see page 78 for more information). Car-

buretors 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.

NOTICE: A main jet that’s too small will cause a lean operating condition and

may cause serious engine damage. Jet the carburetors carefully for

elevation and temperature according to the jetting charts. See your

Owner’s Manual Supplement.

Tip: It’s the owner’s responsibility to ensure that the correct jets are installed in

the machine for a geographical area. Be very careful when jetting down in

warm weather. As the weather turns colder it will be necessary to re-jet

upward to prevent engine damage. When selecting the proper main jet

always use the lowest elevation and temperature that is likely to be encoun-

tered.

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OPERATION

n Engine Stop Switch

Push down on the engine

stop switch to stop the

engine in an emergency.

This will ground out the

ignition and bring the

engine to a quick stop.

To restart the engine, the

switch must be pulled up

to the ON position.

Stop Switch

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. Test the throttle

safety switch system daily before operation.

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

n Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic machine

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

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor(s) 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 free play 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. Refer to page 58 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

Choke

Floods engine

Half throttle or less

Engine Stop Switch

Throttle Safety Switch

Interrupts ignition circuit

All

WARNING! Excessive or repetitive use of brakes for high speed stops will

cause an overheated brake system. This overheated condition could cause

sudden loss of brakes and/or fire, resulting in serious injury or death. When

traveling on long downhill stretches, pump the brakes. Riding the brakes may

cause the brake system to overheat and result in brake failure.

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OPERATION

Electronic Reverse (PERCt)

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

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

tion setting as described on page 62. 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.

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

panel will indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in

reverse.

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

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

restarted.

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OPERATION

Electronic Reverse (PERCt)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

engage the starter when the engine is running.

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.

Ignition Altitude Setting

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

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

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

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

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

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

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

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OPERATION

Towing

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

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

vehicle if force is applied.

For your safety, do not attempt to using the tow hitch until you’ve read

the following warnings and understand the proper hitch functions.

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

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

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

with a rope.

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

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

toboggan or sled, make sure the pole is at least four feet (1.2 meters)

long to prevent any possibility of contact between the snowmobile’s

track and a person riding in the towed object.

Braking distances increase when towing loads. Slow down to maintain

control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn’t

possible to use a rigid tow bar, attach the tow rope to the ski spindles

(not to the ski loops) to prevent damage to the steering components.

Remove the drive belt before towing, and have a rider on the towed

snowmobile to operate the brake and steering when necessary.

NOTICE: Towing a disabled snowmobile with the drive belt in place can result in

serious damage to the engine and drive system. Always remove the

drive belt from a disabled snowmobile before towing.

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MAINTENANCE

Emission Control Information

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

repair the emission control devices or systems on your snowmobile.

Emission Control Label

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

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

tion hang tag. 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 hang tag,

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

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

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

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

qualified dealer for diagnostic service. Specifications and adjustments

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

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

be engaged during engine tune-ups.

Owner's Responsibilities

Please read the 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 124.

The recommended maintenance schedule on your snowmobile calls for

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

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

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

mance and component life, continue maintenance checks at 1000 mile

(1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

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

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

occur as a result of owner neglect in performing recommended regular

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

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

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

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

able performing these tasks yourself, contact an authorized Polaris

dealer for service.

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

exhaust system and engine have cooled before tipping the snowmo-

bile on its side for service or inspection.

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MAINTENANCE

Periodic Maintenance Interval Table

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

may need to increase frequency based on riding conditions. When

inspection reveals the need for replacement parts, always use genuine

Polaris parts, available from your Polaris dealer.

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

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

Season

CLUTCH

Clutch Offset Alignment

(without belt)

Drive Belt Condition

Clutches (disassemble)

Belt Tension

Clutch Sheaves

ENGINE

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

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

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

Season

BRAKES

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads

Brake Disc

Parking Brakes

Brake System

Brake fluid

45,81

FUEL MANAGEMENT

Pilot Air Screws

Carburetor (synchronize)

Idle RPM

Throttle Lever

44,59

Oil Pump Lever

(synchronize)

Throttle Cable

Choke Cable

Vent Lines

Throttle Position Sensor

Choke

N/A

Fuel Filter

Fuel Lines

Oil Filter

Oil Lines

Oil Change

Air Box

Drain and Water Traps

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

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

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

Season

ELECTRICAL

Auxiliary Shut-Off Switch

Throttle Safety Switch

Ignition Switch

Taillight

44,58

Brakelight

Headlight

CHASSIS

Ski Toe Alignment

Suspension Mounting

Bolts

Steering Fasteners

Rear Suspension

Fasteners

Suspension Shock Oil

Cooling Fins and Shroud

Drive Shaft Bearings

Skags (Wear Bars)

Ski Saddle/Spindle Bolts

Ski Pivots

Ski Spindle

Steering Arm(s)

Upper/ Lower Steering

Post Support Bracket

Hood Straps

101

Battery Fluid Level

Rear Wheel Idler Bolts

and Nuts

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

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

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

Season

CHASSIS

Rear Suspension Pivot

Shafts

Camber Alignment

Radius Rod Bushings

Handlebar Centering

Track Alignment

Track Tension

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

100

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

Front Suspension

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. See page 109 for the part numbers of

Polaris products.

The illustration shows the location of suspension and steering compo-

nents. A + indicates a grease point or fitting.

• 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 center steering arms.

• Grease the steering post lower pivot.

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

A grease gun kit, complete with grease and adaptors, is available to

lubricate all fittings on Polaris snowmobiles. See page 109.

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MAINTENANCE

Lubrication

Rear Suspension

The suspension pivot shafts should be lubricated with Polaris Premium

All Season Grease at 500 miles (800 km) initially, every 1000 miles

(1600 km) after that, and before off-season storage each year. Lack of

lubrication will adversely affect your ride and the life of the suspension.

For detailed information about suspension lubrication and adjustments,

see your Polaris dealer.

Tip: The following illustrations are general representations. Your model may dif-

fer. Lubrication points are indicated by a +.

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MAINTENANCE

Lubrication

Jackshaft Bearing

The jackshaft bearing on your model may be equipped with a grease fit-

ting, but this component is greased for life at the factory. Additional

lubrication is not required.

Driveshaft Bearing

Inject grease into the fitting on the

speedometer drive adaptor until

grease purges from inside or outside

the bearing seal (approximately two

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 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 Level

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

nance charts beginning on page 66. 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 109 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on

a level surface.

Magnetic

Plug

Dipstick

2. Remove the dipstick

and view the oil level

on the dipstick.

3. Add the recommended

oil as needed. Do not

overfill.

4. Clean the magnetic

plug.

5. Reinstall the dipstick.

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MAINTENANCE

Spark Plugs

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

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

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

malfunctioning.

In selecting a spark plug heat range for production, a manufacturer

assumes that the engine will be operated under extreme heavy duty con-

ditions and selects a spark plug that will protect the engine from internal

damage if the purchaser actually does operate the engine in this manner.

This selection could cause the customer who normally operates the

engine under medium or light duty to have spark plug failure.

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

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

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

snowmobile. See your Owner’s Manual Supplement.

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

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

which cause plug fouling and carbonization.

• Use recommended spark plugs with the proper gap. See your Owner’s

Manual Supplement.

• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).

• Always carry spare spark plugs.

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MAINTENANCE

Spark Plugs

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

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

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

spark plug for correct color.

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

protective gloves when removing a spark plug for inspection.

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

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

main jet is installed in the carburetor(s). See your Owner’s Manual Supple-

ment.

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.

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

caused by use of an improper spark plug or incorrect carburetion adjust-

ments.

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. Wear protective gloves.

2. Remove the spark plug cap.

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

spark plug counterclockwise to remove it.

4. Reverse the procedure for spark plug installation. Torque to 18-22

ft. lbs. (24.4-29.8 Nm).

5. Reinstall the spark plug cap.

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MAINTENANCE

Intake Filter

The intake foam filter and screen limits snow ingestion into the intake

system. When operating in loose powder snow, check the top of the

foam filter and screen periodically to remove any accumulation of snow.

NOTICE: Operating the snowmobile with the intake filters removed may cause

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

malfunction. Always reinstall the intake filters before operating the

snowmobile.

These illustrations are general representations.Your model may differ.

Foam Filter

Intake

Foam Filter and Screen

Air Intake Box

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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 about every 1000 miles (1600

km) and inspected for contamination.

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

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

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

gasoline warnings found on page 53.

Plug Cleaning Procedure

1. Turn the fuel 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 the traps have been

emptied.

Drain

Plug

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MAINTENANCE

Carburetor

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

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

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

jet is installed.

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

engine damage. Have your Polaris dealer perform all carburetor

adjustments to ensure all adjustments are done correctly.

Carburetor Adjustments

The frequency at which the carburetors are synchronized or balanced is

important. Properly adjusted carburetors can greatly improve engine

performance, fuel economy, engine life, and reliability.

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

adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

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MAINTENANCE

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.

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

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

or kinked, replace it promptly.

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

Exhaust System

Check the exhaust system for wear or damage at approximately 1000

miles (1600 km). To inspect, allow the engine and exhaust system to

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

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

damper/support grommets.

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

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

running.

Drive Chain Tension

To obtain correct chain tension:

1. Rotate the driven clutch coun-

terclockwise to move all chain

Adjuster

Bolt

slack to the tensioner side.

Lock the brake lever lock, or

have an assistant hold the

brake lever firmly.

2. Loosen the adjuster bolt jam

Jam

Nut

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.

5. The chain is now tensioned.

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 45.

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

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

available for replacing brake pads. See your dealer.

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

Properly functioning brakes are vital to your safety. Be sure the brake pads do

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

brake pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16 inch/1.5 mm).

Brake Components

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material

(Replace when thickness is

less than 1/16 inch/1.5 mm)

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MAINTENANCE

Brakes

Brake Fluid

WARNING! After opening a bottle of brake fluid, always discard any unused

portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it

rapidly absorbs moisture from the air. The moisture causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and

the possibility of accident or severe injury.

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

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

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

Keep the master cylinder cover free of dirt and debris. The vent slits

allow for diaphragm movement, and if they become plugged, movement

of brake fluid below the diaphragm may be restricted, altering brake

function.

We recommend the use of Polaris DOT 4 high temperature brake fluid.

See page 109 for the part numbers of Polaris products.

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

up spills immediately.

Replace brake fluid at least every two years.

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MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of

brakes, which could cause an accident and lead to serious injury or death.

Never operate the vehicle with a spongy-feeling brake lever.

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

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

air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

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

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

opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion

and may cause the brakes to lock, resulting in serious injury or death. Always

add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.

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 two (2) inches (5.1 cm) below the mark

placed on the wall in step 4.

Tip: 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

2 in. (5.1 cm)

Adjustment

Nut

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MAINTENANCE

Lights

NOTICE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a

residue, causing a hot spot that will shorten the life of the lamp. If fin-

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

Removing Halogen Bulbs

1. Pinch the ends of the spring (1)

together and lift until it releases

from the spring retainer.

2. Lift spring carefully around

wire harness (2) and flip to out-

side of housing.

3. With the wire harness attached

to the bulb (3), withdraw bulb

from housing.

4. Grasp bulb by metal base and

carefully separate bulb from

harness.

Installing Halogen Bulbs

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

2. Insert bulb into housing.

3. Carefully flip spring back into housing placing it around wire har-

ness.

4. Squeeze spring together until it is over the spring retainer and

release.

5. Verify headlight aim.

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MAINTENANCE

Clutch System

Periodically inspect the clutch sheaves for damage, wear, or belt resi-

due. To maintain optimum performance, clean with non-oil based clean-

ers such as isopropyl alcohol.

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

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

operate the machine until repairs have been made. All clutch mainte-

nance and repairs must be performed by an authorized Polaris dealer.

Any unauthorized modifications to clutches, such as adding or remov-

ing weights, will void the warranty.

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

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

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MAINTENANCE

Clutch System

n Drive Belt Condition

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

sheave width of the drive clutch. For this reason, Polaris recommends

that only O.E.M. belts be used. Other belts may match the dimensions,

but can drastically change the shift pattern, resulting in poor perfor-

mance. See Belt Troubleshooting on page 111.

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.

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

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

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

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

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

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal.

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. Rotate the driven clutch counter-

clockwise 1/4 turn by hand to

ensure forward engagement

before attempting to remove the

belt.

7. 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.

8. 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.

Tip: To ensure satisfactory belt life,

install belts so they operate in

the same direction of rotation

by positioning the identification

numbers so that you can read

them. If required, separate the

sheaves as outlined in the belt

removal procedures.

2. 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 on the

belt (1) and apply downward

pressure while measuring at

point 2. This measurement

should be 1 1/4 inches (32

mm).

Drive Belt Adjustment

Belt deflection should 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.

Tip: 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

Periodically check torque stop

clearance. With clutches in

proper alignment, the torque stop

clearance should be .010-.030

inch (.25-.75 mm) from the

engine case.

.010-.030 in.

(.25-.75 mm)

Adjust if necessary, and lock the

jam nut.

Tool Kit

A tool kit is included with each

machine for emergency and rou-

tine maintenance. Always keep

the tool kit with the snowmobile.

Chain Tension

Maintain the proper chain tension as outlined on page 80.

Fall Tune-Up

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

Polaris dealer.

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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

snowmobile off the ground.

2. Rotate the track by hand to

check for possible damage.

3. Carefully examine the track

along the entire length of

each rod (+). Bend the

track to check for break-

age.

4. Replace the track if any rod

damage is found.

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MAINTENANCE

Track

Track Lubrication

WARNING! Operating with insufficient lubrication between the rail slide and

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

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

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

lubrication.

The slide rail requires adequate snow cover for sufficient lubrication.

Excessive wear indicates insufficient lubrication. A new rail slide can

cause faster heat build-up in limited lubrication, resulting in excessive

wear.

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

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

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

lubrication conditions will void the track warranty.

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MAINTENANCE

Track

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. Tension adjustments should be made only

after the track is warmed up and limber.

WARNING! Improper track tension can cause serious damage to the

snowmobile, which can result in loss of vehicle control and serious injury or

death. Always maintain the track tension as specified.

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

idler wheel.

4. Measure at the point where the weight is hanging.

Weight

Measurement

Location

Measurement

10 lbs. (4.54 kg)

16 inches (41 cm) ahead of

rear idler shaft

3/8-1/2 inch (1-1.3 cm)

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

and the plastic rail slide.

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MAINTENANCE

Track

Track Tension

If the track needs adjustment:

6. Loosen the rear idler

shaft bolt.

Slack

Measurement

Locknut

7. Loosen the locknuts.

Idler Shaft

Adjusting

Screw

8. Tighten or loosen the

track adjusting screws

as necessary to pro-

vide equal adjustment

on both sides of the

track.

Bolt

9. Repeat the measure-

ment on the other side

of the track.

Track

16 in. (40 cm)

Tip: Check more frequently

10 lbs. (4.54 kg)

when machine is new.

10. Start the engine and

slowly rotate the track

at least five revolutions. Let the track come to a stop (do not apply

brakes).

11. Check track alignment (see page 96) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolts. Torque 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).

Rails

3. Inspect track alignment by looking through the track window to

make sure the rails are evenly spaced on each side. If the track runs

to the left, loosen the left locknut and tighten the left adjusting bolt.

If the track runs to the right, loosen the right locknut and tighten the

right adjusting bolt.

4. After adjustments are complete, tighten locknuts and torque idler

shaft bolts to 35 ft. lbs. (47.5 Nm).

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

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MAINTENANCE

Steering System

Steering Inspection

Each week, or before a long ride, check fasteners and tighten if neces-

sary. Specific fasteners that should be checked are marked with a + in

the illustration.

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MAINTENANCE

Steering System

Ski Alignment

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to change the ski

alignment or camber adjustment. See your Polaris dealer.

With the handlebars in a straight-ahead position, and with vehicle

weight compressing the suspension, measure from the straight edge of

the skis at the center of the ski mounting bolt. The measurement

between the skis at point X should be 1/8-1/4 inch (3-6 mm) greater than

at point Y.

Tip: If the skis are misaligned, we recommend that your dealer correct the align-

ment, since camber adjustment may also be affected.

10 in. (25.4 cm)

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MAINTENANCE

Steering System

n Ski Skags

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

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

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

trol while turning on hard-packed snow or ice.

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

vehicle control may result, causing serious injury or death. Replace skags as

recommended.

Check skags weekly to maintain positive steering characteristics. Skags

must be replaced when worn to half their original diameter. Carbide

skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

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

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MAINTENANCE

Suspension Maintenance

n Rail Slide Wear

For ease of inspection, all

Polaris rail slides have a

wear limit indicator groove

to indicate the minimum per-

missible slide thickness.

Minimum

Thickness

Replace the rail slides if they

are worn to the top of the

groove at any point along

their length. Failure to do so

may result in permanent

Replace when

worn to top of

groove

damage to the track or rails.

Suspension Inspections

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 95.

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 94.

n Lubricate/grease all suspension components. See page 70.

n Check ski runner/skag condition. See page 99.

n Check ski spindle bolts for tightness.

n Check tie rod end nuts for tightness.

100

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MAINTENANCE

Battery

WARNING

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

contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi-

cal attention.

KEEP OUT OF REACH OF CHILDREN.

EXTERNAL: Flush with water.

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

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 Fluid

A poorly maintained battery will

Upper Mark

deteriorate rapidly. Check the battery

fluid level often. The fluid level

should be kept between the upper and

lower level marks.

NOTICE: Tap water contains minerals

Lower Mark

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.

101

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MAINTENANCE

Battery

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.

Battery Removal

WARNING! Improperly connecting or disconnecting battery cables can result in

an explosion 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 the battery hold-down straps.

2. Remove the battery vent tube from battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable last.

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

ways or spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one table-

spoon baking soda and one cup water to prevent damage to the vehi-

cle.

102

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MAINTENANCE

Battery

Battery Installation

WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte

as severe burns may result.

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder. Attach the hold down strap.

3. Install the battery vent tube. The vent tube must be free of obstruc-

tions and securely installed. Route the vent tube properly to prevent

kinks and to allow for proper drainage.

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

pinched or kinked, battery gases could accumulate. Always ensure that the vent

tube is free of obstructions and is securely installed as recommended.

Whenever removing or installing the battery, disconnect the negative (black)

cable first and reinstall the negative cable last to avoid the possibility of

explosion.

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

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

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

7. Verify that cables and vent tube are properly routed.

103

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MAINTENANCE

Battery

Battery Storage

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

summer or in winter):

• Remove the battery.

• Charge it to the proper level.

• Store it in a cool dry place.

• Check and/or charge monthly.

• Have the battery tested and recharged before reinstalling it in the

vehicle.

If a battery with a low charge freezes, the cells could be damaged.

Always maintain a full charge on a stored battery. See the table below.

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)

104

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MAINTENANCE

Daily Storage

At the end of each ride, park the snowmobile

on a level surface and support it at the rear

with an appropriate track stand. The track

should be suspended approximately 4 inches

(10 cm) off the ground.

Remove the key and cover the machine.

Tip: Polaris has accessory covers and track stands

available to fit all models. See your dealer for

more information.

105

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MAINTENANCE

Extended Storage

Off-season or extended storage of your snowmobile requires preventive

measures to aid against deterioration and to prolong the useful life of

many components.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood,

chassis, and plastic parts. Wipe down remaining surfaces with a damp

cloth. Clean and touch up with paint any rusted or previously painted

surfaces. Be sure that corrosive salt and acids are removed from surfaces

before beginning preservation with waxes and rust inhibitors (grease, oil

or paint).

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

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

cause condensation to form and damage snowmobile components.

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 can. See page 107.

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

the fuel tank. Follow the instructions on the can, running the engine for

five minutes to get additives through the entire fuel system. Top off with

fresh fuel.

Tip: For easier starting after extended storage, add lubricant to the fuel in the

tank at a 40:1 ratio and run the engine for three to five minutes before stor-

age. This will lubricate the fuel pump diaphragm to keep it flexible and help

prevent loss of prime.

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

drain plugs (see page 77). Catch fuel in a container or shop cloth. Rein-

stall plugs securely. Observe all fire safety rules when draining carbure-

tors. See gasoline warnings on page 53.

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

very poor slow speed driving quality.

106

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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 to 5 on remaining cyl-

inders.

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

Controls and Linkage

All bushings, spindle shafts, tie rod ends, and cables should receive a

light coat of oil or grease.

Bearings

Grease the drive shaft clutch side bearing with Polaris Premium All-

Season Grease or a similar high quality grease to prevent corrosion. See

page 109 for part numbers.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Lubricate the

sheave faces of the drive and driven clutches with a light coat of oil or

Polaris Cable Lubricant. See page 109 for the part numbers of Polaris

products. Do not lubricate clutch components, except the driven clutch

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

107

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MAINTENANCE

Extended Storage

Electrical Connections

Separate electrical connector blocks and clean corrosive build-up from

connectors. Lubricate or pack connector blocks with dielectric grease

and re-connect. See page 109 for the part numbers of Polaris products.

Replace worn or frayed electrical wire and connectors. Be sure wiring

harness is properly secured away from sharp edges, steering linkage,

moving parts, and hot exhaust parts.

Battery

Always prepare and maintain the battery as outlined on page 101.

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.

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.

108

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POLARIS PRODUCTS

Description

Part No.

Engine Lubricants

2870791

2871098

2871097

2871240

2871721

2871722

2872347

Fogging Oil (12 oz. Aerosol)

Premium 2-Cycle Engine Oil (qt.)

Premium 2-Cycle Engine Oil (gal.)

Premium 2-Cycle Engine Oil (2.5 gal.)

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

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

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

Chaincase Lubricants

2873105

2872951

Synthetic Chaincase Lubricant (qt.)

Synthetic Chaincase Lubricant (12 oz.)

Grease / Specialized Lubricants

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

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Dielectric Grease (Nyogel™)

2871312

2871322

2871423

2871329

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

109

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SUSPENSION TROUBLESHOOTING

Problem

Solution (perform only one change at a time)

Rear suspension bot- • Verify sag dimension (see page 34). Adjust torsion spring

toms too easily

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Increase shock compression damping (see page 37).

Rear suspension

rides too stiff

• Check for binding suspension components and grease all

pivot points.

• Verify sag dimension (see page 34). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Decrease shock compression damping (see page 37).

Too much weight

transfer when climb-

ing

• Verify sag dimension (see page 34). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Move limiter strap on front torque arm to high position (see

page 36).

Too little weight

transfer when climb-

ing

• Verify sag dimension (see page 34). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Move limiter strap on front torque arm to low position (see

page 36).

Front end pushes

• Check for worn skags

• Check for binding front suspension shafts and steering com-

ponents, grease all pivot points (elevate front of machine).

• Verify sag dimension (see page 34). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Increase IFS preload (see page 32).

• Move limiter strap on front torque arm to high position (see

page 36).

Steering is heavy

• Check skags and skis for damage.

• Check for binding front suspension shafts and steering com-

ponents, grease all pivot points (elevate front of machine).

• Verify sag dimension (see page 34). Adjust torsion spring

blocks or install optional torsion springs to achieve correct

sag dimensions.

• Decrease IFS preload (see page 32).

Machine darts from • Ensure skis are properly aligned (see page 98).

side to side

• Check for binding front suspension shafts and steering com-

ponents, grease all pivot points (elevate front of machine).

• Ensure skags are straight on skis.

110

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TROUBLESHOOTING

Belt Wear/Burn 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. Remove windage plates from the

clutch. Reduce RPM. Avoid riding in high ambient

temperatures.

Ice and snow build-up

between track and

tunnel

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

off the machine in extremely cold weather and warm it up.

Break machine loose from the snow.

Poor engine

performance

Check for carb and choke synchronization, fouled plugs,

debris in the carbs, and water, ice or dirt in the gas tank or

fuel line.

Loading machines

onto trailers

Skis may gouge into trailers and prevent the drive train

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

engagement

111

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TROUBLESHOOTING

Engine Troubleshooting

CAUTION: Unless you have experience and training in two-cycle

engine repair, see your dealer if technical problems arise.

Problem

Probable Cause Solution

Erratic engine

operating RPM

during acceler-

ation or load

variations

Drive clutch binding

• Disassemble drive clutch to inspect shift

weights for wear and free operation.

SEE YOUR DEALER.

• Clean and polish stationary shaft hub.

Driven clutch

malfunction

• Replace ramp buttons and rollers. SEE

YOUR DEALER.

• Inspect movable sheaves for excessive

bushing clearance and replace if neces-

sary. SEE YOUR DEALER.

Harsh drive

Drive belt worn or too • Replace drive belt.

clutch engage- narrow

ment

Excessive belt/sheave

• SEE YOUR DEALER.

clearance

Drive belt turns Wrong belt for applica- • Replace drive belt.

over

tion

Clutch alignment out

of spec

• Adjust alignment offset.

Engine mount broken

or loose

• Inspect and adjust or replace. SEE

YOUR DEALER.

Machine fails

to move

Clutch jammed

• Belt twisted, spring broken, weights

stuck, lubricated. SEE YOUR

DEALER.

Track jammed

• Foreign object caught or rail slide

melted to track clips due to lack of

lubrication.

• Machine may be frozen to ground.

Track may be iced up.

Chaincase sprocket or

chain jammed or bro-

ken

• Chain is loose or broken, chain tight-

ener is loose. SEE YOUR DEALER.

112

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive

system

Broken drive clutch

components

• SEE YOUR DEALER.

Bearing failure/ chain- • SEE YOUR DEALER.

case, jackshaft, or front

drive shaft

Drive belt surface flat

spots

• Inspect and replace if necessary.

Drive chain loose or

worn, sprocket teeth

broken

• Inspect and adjust or replace.

Poor low RPM Worn drive belt

performance

• Inspect and replace if necessary.

• SEE YOUR DEALER.

Excessive belt/sheave

clearance

Loose torque stop

Sticky clutch

• Inspect and adjust.

• SEE YOUR DEALER.

Engine doesn’t Wire connections

start (electric

start models)

Engine doesn’t Seized engine

turn

• SEE YOUR DEALER. Seizure is a

result of poor lubrication, inadequate

fuel supply, broken parts, or improper

cooling.

Hydrostatic lock

• Fuel may have entered crankcase

while vehicle was standing or being

transported. SEE YOUR DEALER to

correct cause. Drain plug(s) are

located on lower crankcase for emer-

gency draining.

113

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause

Solution

Engine turns

but fails to start

Faulty ignition

• Remove spark plug(s) and replace

with new plug(s). If engine still fails

to start, check for spark; if no spark

SEE YOUR DEALER.

No fuel to engine

• Make sure the fuel valve is ON.

Check tank level and fill up with cor-

rect fuel.

• Ice in fuel line, filter, or pump. On the

standard Polaris carburetor, the choke

will not function with the throttle

depressed. See second item under

“Probable Cause” of “Engine contin-

ually backfires”.

Flooded engine (normal • Hold throttle open, crank engine sev-

situation caused by too

much choking)

eral times (may be necessary to

change plug(s), however, the plug(s)

may operate satisfactorily when

dried).

Poor engine compression • Running too lean a mixture (too small

a main jet will cause seizure resulting

in loss of power). SEE YOUR

DEALER. This indicates a major

engine problem that must be repaired

before engine is run.

Engine lacks

power

Fouled or defective

spark plug

• Change and test operation.

Fuel filter (loss of high

RPM power)

• Check fuel filter flow. Disconnect

hose and drain about 1/2 cup. Fuel

flow should be steady and encompass

the entire diameter of fuel line. If not,

replace filter.

Incorrect clutching

• SEE YOUR DEALER.

Carburetor and fuel

pump

• There’s no adjustment to change

power output. SEE YOUR DEALER.

Engine continu- Faulty plug(s)

• Change plug(s)

ally backfires

Carburetor

• Dirt or ice in fuel system. (Deicer

should be added to non-ethanol fuel

at all times for assurance against fuel

line icing.)

Engine requires Poor gasoline or not

more than nor- enough fuel getting to

• Replace with fresh winter fuel.

mal pulls to

start

engine

114

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WARRANTY

Service And Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the Polaris warranty informa-

tion contained in this manual. Contact your Polaris dealer for replace-

ment parts, service or warranty. Your dealer receives frequent updates

on changes, modifications and tips on snowmobile maintenance, which

may supersede information contained in this manual. Your dealer is also

familiar with Polaris policies and procedures and will be happy to assist

you.

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

following information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

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

the identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-888-704-5290

Canada: 1-204-925-7100

115

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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.

116

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WARRANTY

Limited Warranty

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

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

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

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

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

ranty period, through a Polaris dealer.

Registration

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

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

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

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

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

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your snowmobile is very important in ensuring

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

set-up will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

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

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

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

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

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

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

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

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

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

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

are not compatible with the snowmobile.

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

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

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

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

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL

OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF

EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-

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

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

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

state law.

117

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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.

118

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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.

119

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WARRANTY

Polaris Second Year Engine Service Contract

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

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

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

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

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

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

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

istration form. This form is your proof of warranty.

Consumer Exclusions

• Each repair visit after the first twelve months of standard warranty coverage is subject

to a $50 deductible.

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

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

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

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

program.

• Snowmobiles used for commercial purposes or for racing are excluded from coverage.

Coverage

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

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

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

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

validate this warranty.

A partial list of items excluded from coverage includes:

• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.

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

• Failures caused by improper fuel or oil.

• Piston seizures, unless caused by a defective engine component.

• Failures caused due to improper adjustments.

• Failure due to unauthorized service.

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

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

• Failure due to use of unauthorized parts or modifications.

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

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

exhaust manifolds excluding paint coverage.

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

and other electrical components are excluded from coverage.

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

fan bearings, temperature sensor, gasket and seals.

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

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

excluded from coverage.

• Electrical components are excluded from coverage.

• Gearcases and transmissions are excluded from coverage.

120

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

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

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

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

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

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

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

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

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

form the warranty repair.

If You Move:

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

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

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

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

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

to register your vehicle in your new country.

If Purchased From A Private Party:

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

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

Notice

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

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

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

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

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

For questions call Polaris Customer Assistance (see page 115).

121

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the Polaris standard limited warranty

for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this

emissions-certified vehicle is designed, built and equipped so it conforms with applica-

ble U.S. Environmental Protection Agency emission regulations. Polaris warrants that

the vehicle is free from defects in materials and workmanship that would cause it to fail

to meet these regulations.

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

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

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

whichever comes first.

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

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

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

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

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

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

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

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

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

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

sions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

122

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

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

option of Polaris, repair or replacement of any defective materials, components or prod-

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

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

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

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

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

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

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

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

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

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

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

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

Owners are responsible for performing the scheduled maintenance identified in the

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

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

has no responsibility, or by acts of God.

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

trol devices or systems on your vehicle. Polaris recommends that you contact an autho-

rized Polaris dealer to perform any service that may be necessary for your vehicle.

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

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

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

prohibited by federal law.

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

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

123

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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)

124

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

125

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

126

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

127

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INDEX

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

Air Box Warning . . . . . . . . . . . . . . . 23

Air Pollution . . . . . . . . . . . . . . . . . . . 6

Apparel . . . . . . . . . . . . . . . . . . . . . . 12

Avalanches. . . . . . . . . . . . . . . . . . . . 15

Disabled Operators . . . . . . . . . . . . . . 13

Drive Belt

Safety. . . . . . . . . . . . . . . . . . . . . 18

Adjustment . . . . . . . . . . . . . . . . 90

Condition . . . . . . . . . . . . . . . . . . 87

Deflection . . . . . . . . . . . . . . . . . 90

Installation . . . . . . . . . . . . . . . . . 89

Removal. . . . . . . . . . . . . . . . . . . 88

Drive Chain Tension . . . . . . . . . . . . . 80

Driver Awareness . . . . . . . . . . . . . . . 14

Driving Downhill. . . . . . . . . . . . . . . . 18

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 16

Driving Responsibly . . . . . . . . . . . . . 21

Battery . . . . . . . . . . . . . . . . . . 101-104

Connections . . . . . . . . . . . . . . 102

Fluid. . . . . . . . . . . . . . . . . . . . 101

Installation . . . . . . . . . . . . . . . 103

Removal. . . . . . . . . . . . . . . . . 102

Storage. . . . . . . . . . . . . . . . . . 104

Brakes . . . . . . . . . . . . . . . . . . 45, 81-83

Components. . . . . . . . . . . . . . . 81

Fluid. . . . . . . . . . . . . . . . . . . . . 82

Inspection. . . . . . . . . . . . . . . . . 81

Lever Feel . . . . . . . . . . . . . . . . 45

Lever Travel. . . . . . . . . . . . . . . 45

System Bleeding . . . . . . . . . . . 83

Break-In Period . . . . . . . . . . . . . . 50-51

Emission Control Information. . . . . . 64

Emissions Limited Warranty. . 122-123

Engine Break-In. . . . . . . . . . . . . . 50-51

Engine Care for Storage . . . . . 106-107

Environment . . . . . . . . . . . . . . . . . . . . 6

Exhaust . . . . . . . . . . . . . . . . . . . . . . . 53

Exhaust System . . . . . . . . . . . . . . . . . 80

Carburetion . . . . . . . . . . . . . . . . . 56-57

Carburetor . . . . . . . . . . . . . . . . . . 77-78

Carburetor Adjustments. . . . . . . . . . 78

Carburetor Protection (Storage) 106-107

Carburetor Trap . . . . . . . . . . . . . . . . 77

Cargo . . . . . . . . . . . . . . . . . . . . . . . . 13

Chain Tension . . . . . . . . . . . . . . . . . 91

Choke. . . . . . . . . . . . . . . . . . . . . . . . 49

Cleaning the Vehicle . . . . . . . . . . . 106

Clutch Alignment. . . . . . . . . . . . . . . 86

Clutch Center Distance . . . . . . . . . . 86

Clutch Cover Warning. . . . . . . . . . . 23

Clutch Guard . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . . . 86-91

Clutches . . . . . . . . . . . . . . . . . . . . . . 19

Cold Weather Drive-Away . . . . . . . 19

Fuel . . . . . . . . . . . . . . . . . . . . . . . 53-54

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 79

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 79

Fuel Recommendations . . . . . . . . . . . 54

Fuel Reserve . . . . . . . . . . . . . . . . . . . 54

Fuel System Deicers . . . . . . . . . . . . . 54

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27

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

Headlight Adjustment . . . . . . . . . . . . 84

Hood Latches. . . . . . . . . . . . . . . . . . . 47

128

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INDEX

Ice and Snow Build-up . . . . . . . . . . . 16

IFS Adjustment Options . . . . . . . . . . 29

IFS Components . . . . . . . . . . . . . . . . 29

Ignition Altitude Settings . . . . . . . . . 62

Intake Filter. . . . . . . . . . . . . . . . . . . . 76

Intake Silencer . . . . . . . . . . . . . . . . . 19

Parking Brake Lever Lock . . . . . . . . 46

Passenger Warning . . . . . . . . . . . . . . 23

Periodic Maintenance Table . . . . 66-69

Polaris Products . . . . . . . . . . . . . . . 109

Pre-Ride Checklist . . . . . . . . . . . . . . 43

Pre-Ride Inspections. . . . . . . . . . 43-48

Jetting Guidelines . . . . . . . . . . . . . . . 57

Rail Slide Wear. . . . . . . . . . . . . . . . 100

Recoil Rope . . . . . . . . . . . . . . . . . . . 47

Reverse Operation . . . . . . . . . . . 61-62

Reverse Warning . . . . . . . . . . . . . . . 24

Riding Position . . . . . . . . . . . . . . . . . 12

Lights . . . . . . . . . . . . . . . . . . . . . 84-85

Headlight Adjustment. . . . . . . . 84

Installing Halogen Bulbs . . . . . 85

Removing Halogen Bulbs. . . . . 85

Lubrication

Safety . . . . . . . . . . . . . . . . . . . . . . 8-22

Safety Decals . . . . . . . . . . . . . . . 23-25

Safety Symbols . . . . . . . . . . . . . . . . . . 8

Sag . . . . . . . . . . . . . . . . . . . . . . . 34-35

Shock Components . . . . . . . . . . . . . . 30

Shock Compression Damping . . . . . 37

Shock Spring Preload . . . . . . . . . . . . 32

Signal Words . . . . . . . . . . . . . . . . . . . 8

Ski Alignment. . . . . . . . . . . . . . . . . . 98

Ski Skags . . . . . . . . . . . . . . . . . . . . . 99

Slide Rail . . . . . . . . . . . . . . . . . . . . . 53

Snow Conditions. . . . . . . . . . . . . . . . 20

Spark Plugs . . . . . . . . . . . . . . . . . 74-75

Speed. . . . . . . . . . . . . . . . . . . . . . . . . 13

Spring Preload, Rear. . . . . . . . . . 34-35

Springs, Front . . . . . . . . . . . . . . . . . . 31

Starting the Engine . . . . . . . . . . . . . . 49

Steering Inspection . . . . . . . . . . . . . . 97

Steering System . . . . . . . . . . 47, 97-99

Stop Switch. . . . . . . . . . . . . . . . . . . . 58

Stopping, Emergency . . . . . . . . . . . . 60

Choke and Cable. . . . . . . . . . . . 72

Driveshaft Bearing . . . . . . . . . . 72

Front Suspension. . . . . . . . . . . . 70

Jackshaft Bearing . . . . . . . . . . . 72

Rear Suspension . . . . . . . . . . . . 71

Throttle Cable . . . . . . . . . . . . . . 72

Maintenance Program. . . . . . . . . . . . 65

Maneuverability . . . . . . . . . . . . . . . . 19

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 79

Oil Indicator Light . . . . . . . . . . . . . . 55

Oil Level . . . . . . . . . . . . . . . . . . . . . . 55

Oil Level, Chaincase. . . . . . . . . . . . . 73

Oil Recommendations. . . . . . . . . . . . 51

Operating in Deep Snow. . . . . . . . . . 20

Operation Warning . . . . . . . . . . . . . . 25

129

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INDEX

Storage, Daily . . . . . . . . . . . . . . . . 105

Storage, Extended . . . . . . . . . . 106-108

Survival Preparation . . . . . . . . . . . . 11

Suspension

Track

Alignment . . . . . . . . . . . . . . . . . 96

Cooling . . . . . . . . . . . . . . . . . . . 53

Damage . . . . . . . . . . . . . . . . . . . 47

Inspection. . . . . . . . . . . . . . . . . . 92

Lubrication. . . . . . . . . . . . . . . . . 93

Tension . . . . . . . . . . . . . 33, 94-95

Warm-Up. . . . . . . . . . . . . . . . . . 52

Track/Seat Warning. . . . . . . . . . . . . . 24

Traction Products. . . . . . . . . . . . . 40-42

Transporting the Snowmobile . . . . . 108

Troubleshooting, Belt Wear . . . . . . 111

Troubleshooting, Engine . . . . . 112-114

Troubleshooting, Suspension. . . . . . 110

Tune-Up. . . . . . . . . . . . . . . . . . . . . . . 91

Adjustments, Front . . . . . . . 29-32

Adjustments, Rear . . . . . . . . 33-37

Inspections. . . . . . . . . . . . . . . 100

Lubrication, Front . . . . . . . . . . 70

Lubrication, Rear. . . . . . . . . . . 71

Performance Tips. . . . . . . . . . . 33

Troubleshooting. . . . . . . . . . . 110

Throttle Lever . . . . . . . . . . . . . . 44, 59

Throttle Safety Switch. . . . . . . . 44, 58

Tool Kit . . . . . . . . . . . . . . . . . . . . . . 91

Torque Stop . . . . . . . . . . . . . . . . . . . 91

Torsion Spring Preload . . . . . . . . . . 36

Towing. . . . . . . . . . . . . . . . . . . . . . . 63

V-W

Vehicle Identification Numbers. . . . . . 7

Wear Strips . . . . . . . . . . . . . . . . . . . . 42

Windchill/Temperature Charts . . . . . 22

130

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