Polaris 700 Classic manual

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W ARNING W ARNING Read, understand, and follow al l of the instructions and safety precautions in thi s manual and on all product labels. Failure to follow t he safety precautions could result in serious inj ury or death. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm. PROPO[...]

1 WELC OME Thank you for purcha sing a Polar is vehicle , and welcome to our world-w ide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cr ea tional produc ts. S Snowmobiles S All-te rr ain ve hicles ( A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Polaris sets a standa rd of exc elle [...]

2 PO L AR IS an d PO L AR IS T HE W A Y O UT are registered t radem ark s of Pol aris Indus t ri e s Inc . RIDER SELECT is a tr a dema r k of Pola r is I ndust r ie s I nc. Copyri ght 2005 Pola r is Sa l es I nc . Al l inf or ma ti on c onta i ned wi t hin t hi s publ i ca t ion i s bas e d on the l at e st pr oduc t inf or ma ti on at the t i me o[...]

3 TABLE OF CONTENTS Introducti on 4 ............................... This section contains helpf ul informa tion for owne rs and drivers a nd illustrate s the loca tion of impor tant identif ica tion numbers tha t should be rec orde d in the owner’ s manual. Safety 7 ..................................... This sec tion desc ribes sa fe ve hicle ope[...]

4 INTRODUCTION Impor tant N otes for Ow ners and D ri vers After r eading this manual, store it in the snowmobile for conve nient ref er enc e. It should re main with th e snowmobile whe n the snowmobile is sold. Some of the illustrations and photos used in this manua l are gene ra l repr ese ntations. Y our model may dif fe r . Follow the maintena[...]

5 INTRODUCTION Pr eser vation of the Envir onm ent Polaris is committe d to supporting a n environme ntal e duca tion campa ign. W e encour age state a nd provincia l governments ac ross the snowbelt to adopt rigor ous safe ty training progr ams that enc ourage protec tion of our e nvironme nt, including wildlife a nd vegeta tion. Snowmobile clubs [...]

6 INTRODUCTION V ehicl e Identificati on Num bers Recor d your snowmobile’ s identific ation number s and ke y number in the s paces pro vi ded. Rem ove t he s pare k ey and st ore i t i n a s afe pl ace. Y our key can be duplica ted only by mating a Polaris ke y blank with one of your existing ke ys, so if both keys ar e lost, the ignition switc[...]

7 SAFE TY Operator S afety The following signa l words and symbols a ppear throughout this manual a nd on your vehic le. Y our sa fety is involve d when the se words and symbols are use d. Become f amilia r with their mea nings befor e rea ding the manual. The safety aler t sy mbol , on your vehicle or in t his manual, alert s you to t he pot entia[...]

8 SAFE TY Operator S afety Follow the re comme nded mainte nanc e progr am outlined be ginning on page 72 of this manua l to ensur e that a ll cr itical c omponents on the snowmobile ar e thoroughly inspec ted by your de aler a t specif ic mi leag e in terv als . W ARNING Driving a s nowmobile requir es your full at t ention. DO NO T drink alcohol [...]

9 SAFE TY Operator S afety Stay Clear of T r ack Y our snowmobile is propelle d by a re volving trac k that must be partia lly expose d for pr oper ope ration. W ARNING Serious injur ies may res ult if hands , feet , or clot hing becom e entangled in the t rack . B e alert when riding, and remain pr operly s eated t o st ay clear of the track. Neve[...]

10 SAFE TY Operator S afety Ridi ng Posi tion Opera ting a snowmobile requir es skill and balance f or proper c ontrol. Rider positions ma y vary w ith expe rienc e; but under most conditions, the prope r position is to be se ated with both f ee t on the running boar ds and both ha nds on the handle bar gr ips for prope r throttle , brake a nd stee[...]

11 SAFE TY Operator S afety Ridi ng Appar el Be p repared, b e warm an d b e comfor table w hen riding. Be aware of th e weath er forecast , es peci all y t he windchill, and dr ess accordi ng ly . See t he ch art on page 20. W ARNING Avoid wearing loose clot hing or long scarves, whi ch can become ent angled in moving par ts and cause s erious inj[...]

12 SAFE TY Operator S afety Rider Capacity Dr iving 1-Up - Some Polaris snowmobiles are de signed for a single rider onl y . A decal on th e console of the se models indic ate s single rider ope ration. Dr iving 2-Up - Some Polaris snowmobile s are designed f or up to two riders . A decal o n t he hood of these models indicate s that the vehicle is[...]

13 SAFE TY Operator S afety Driver A wareness Slow down when trave ling nea r poles, pos ts , or o th er obs t acles . B e es peci all y aler t if you’re snowmobiling afte r dark. Always be on the alert for wir e fenc es. Single strands are e specia lly danger ous, si nce th ere may be a g reat d is tance betwe en posts. Guy wir es on utility pol[...]

14 SAFE TY Operator S afety A valanch es Snowmobilers should alwa ys be pr operly traine d and equippe d bef ore tra veling in mountainous ter rain: S T ake an aval anche cl as s S T ravel wit h exp erienced p eop le S T ravel on de signated tr ails S Make su re each person i s equ ip ped wi th a shovel, probe and a valanche beacon. Y ou don’ t h[...]

15 SAFE TY Operator S afety Ice and S now Buil d - up W ARNING Ice and s now build-up m ay int erfer e with t he st eering of y our machine, res ulting in s erious injur y or deat h. Keep the underhood area f ree of snow and ic e. Befo re dr iving, manually turn the skis to the lef t and right to be sur e ice a nd snow ar e not inter fer ing with f[...]

16 SAFE TY Operator S afety Driving in Hilly T errain W ARNING Climbing a hill or c ross ing the f ace of a slope m ay res ult in los s of balance and mac hine roll-ov er , causing s erious injur y or deat h. Use caut ion and good judgement when driv ing in hilly t errain. Use e xtra cau tion when ope ra ting in hilly terr ain. If climbing a hill i[...]

17 SAFE TY Operator S afety Drive Belt Do not ope r ate t he e ngine wit h the driv e belt r em ove d. Any servic ing that r equire s opera tion without a belt must be pe rfor med by your dea ler . Ope ration of the engine with the belt remove d may result in injur y or dama ge to the e ngine. Intake Silencer Do not oper at e the engine w ith the i[...]

18 SAFE TY Operator S afety Inadequate S now Condi tions W ARNING Do not dr ive for prolonged per iods on black top, grav el, or ice. Doing so could c ause irr evers ible tr ack dam age and lead to serious injur y . Since snow provides the only lubrication for the power slide suspension and, on liquid coole d models, cooling for the engine, adequa [...]

19 SAFE TY Operator S afety Dr ivi ng Res ponsibly Every snowmobile handles dif fere ntly , and eve n the most docile conditions may become danger ous if oper ator s drive impr operly . If you’re ne w to snowmobiling, acqua int yourself with the machine and with wha t it will a nd won’ t do unde r va rious c onditions. Even seasone d driver s s[...]

20 SAFE TY Operator S afety Windchill/T emper ature Charts The following inf ormation is provide d to help you dete rmine w hen temper ature s bec ome dange rous fo r riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Act ual Ther mome ter Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2 0 -25 -30 -35 -40 -4 5 Equivalent T emperatur e ( ° F)[...]

21 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he snowmobil e for your prot ect io n. R ead and fo ll ow t he in st ruct io ns o f the decal s and o th er warnin gs on t he s no wmo bi le careful l y . If any of t he d ecals depi ct ed in thi s manual differ from the decal s on your snowmobile, always read and fo ll [...]

+ 22 SAFE TY Safety D ecals and Locations “No Passenger” W arning Snowmobiles designed for a single rider only hav e a war ning decal on t he co ns ol e bel ow t he stee ring post: W ARNING This vehi cle i s designed f or operat or only . “NO P ASSENGER” Passenger W arning Snowmobiles designed f or an ope rator and one pa ssenger have a war[...]

23 SAFE TY Safety D ecals and Locations Reverse W arning The rev erse warni ng decal i s l ocat ed on the console below the windshield: Reverse operat i on, even at low speeds, may cause l oss of control res u lting in s e riou s in jury o r death. T o avoid loss of control , always: S Look behind befor e and while backing up. S A void shar p tur n[...]

24 SAFE TY Safety D ecals and Locations Operation W arning Op erati on W a rn in g Decal : S T o avoid ser ious injury or deat h, r ead and unders tand all war nings and the O wner ’s Manual before oper ation. I f t he manual is mis sing, contac t a P olaris dealer f or a replac ement . S This vehicle is capable of high speeds . B uried object s [...]

25 FEATURES 1. Hood 2. Headlight 3. Mirro rs 4. Winds hield 5. Handlebar 6. O perat or Seat 7. P assenger S eat (T ouring) 8. P assenger G rab Handle (T ouring) 9. Trunk (T ouring) 10. T aillights 1 1. Rear B umper 12. S now Flap 13. T rack 14. P assenger F oot rest (T ouring) 15. Suspension 16. Nosepan 17. F ront B umper 18. Skis 19. G rab Handle [...]

26 FEATURES 1. F uel F iller Cap 2. I gnit ion Swit ch 3. B rake Lev er 4. M FD G auge 5. Headlight A djust er 6. E ngine St op Swit ch 7. T hrot t le Contr ol 8. Hood Hold Down S tr aps 9. Rec oil St art er Handle 10. Headlight Dimm er Swit ch 11 . P a r k B r a k e 12. Handlebar Gr ip W armer Switc h 13. T humbwar mer Swit ch 14. E lect ronic Rev[...]

27 FEATURES Detonation E lim inati on T echnology (D .E .T .) A detona tion sensor monitors the engine a nd re sponds to detonation by automa tically r educ ing the engine timing and a dding fuel. This re sults in decreas ed eng in e RP M and perfo rman ce. DE T T r oubleshooti ng Use this cha rt to dete rmine cause s and solutions f or detona tion[...]

28 FEATURES RIDE R S E LECT A djustable Steer ing S ystem The RIDER SELEC T adjustable steering system allows you to adjust the handle bar position to fit your style of riding. S ome models have five (5) a djustment positions. Other models have se ven (7) positions. W ARNING If your s nowmobile has five adjustm ent posit ions, do not remove the RI [...]

29 FEATURES RIDE R S E LECT A djustable Steer ing S ystem W ARNING Att empt ing t o adjust the handlebar posit ion while t he snowmobile is mov ing could res ult in los s of cont rol and ser ious injury or death. Always s top t he snowmobile bef ore at t empt ing to adjus t the steerin g system. 1. S top the snowmobile. 2. P ress the rele ase butto[...]

30 FEATURES In st ru men t at io n MFD Com ponent Identific ation Item 1 Analog Gauge 2 Digi tal Gauge 3 Check Engine I ndicat or 4 Low Oil I ndicat or 5 High T emp Indi cat or 6 Brake I ndicat or 7 Reverse I ndi cator 8 High Beam I ndicat or Digital Display Identification Item 1 RPM or Speed Alt it ude (if equi pped) Servi ce Int erval 2 Elect ri [...]

31 FEATURES In st ru men t at io n MFD Settings W ith the engine running, use the MFD Control Switc h (A) to set the MFD display to your pr efe re nce. The rocke r switch has a MODE button (B) a nd a SE T button (C). Stan dard vs. Met ric The MFD will display eithe r standa rd or metric units of meas urem ent . Wh il e vi ewi ng a screen t hat d is[...]

32 FEATURES In st ru men t at io n MFD Digital Display Program s Press the MODE button to cycle through the thre e MFD programs: Perf orma nce , Engine and H istory . Ea ch pr ogram w ill rema in in the display until another is sele cted. NOT E: T he analog will always dis play eit her MP H or engine RPM (whichev er set t ing is selec ted) regardle[...]

33 FEATURES In st ru men t at io n MFD Digital Display Program s Performance Progra m Clock S ettin g 1. While in the CLOCK display , press and hold the SET button for five seconds. 2. When the hour starts fla shing press the SET switch once to advance one hour , or pre ss and hold the SET button to advance the hour once ever y 0.2 seconds. 3. P re[...]

34 FEATURES In st ru men t at io n MFD Digital Display Program s Alt it ude (if e quippe d) The ride r ca n calibr ate the a ltimete r for cur rent atmosphe ric conditions. Altimete r accuracy wil l b e +/ - - 3 00 ft . (9 1 m) after adjustme nt. NOT E: Pr ess and hold t he MO DE s witc h for t en sec onds t o swit ch between st andard and m etr ic[...]

35 FEATURES In st ru men t at io n MFD Digital Display Program s History Progra m The H istory Pr ogram a utoma tically displays ele ctr ical syste m voltage leve l and fu el leve l. While in the Histor y mode, pre ss the SET button to view maximum vehicle spe ed, maximum engine rpm or the curre nt service inte rval s e t t i n g . The gauge automa[...]

36 FEATURES In st ru men t at io n MFD Digital Display Program s Ser vic e Int er va l Rem inder The gauge logs the number of engine hours betwee n service r eminde rs. When the logged hours reaches t he designate d ser vice inte rva l (set by the user) , the gauge provides a reminde r that ser vice is due. “SE rVCE ” will flash in the odometer[...]

37 FEATURES In st ru men t at io n MFD Battery Replacem ent If the cloc k function of the MFD isn’ t worki ng p roperl y , repl ace th e bat tery . Rep lacem ent bat teri es are av ail abl e from your deale r . 1. Remove the plenum from the underside of the hood. 2. Locate the black batte ry comp artm ent (A). It has a red wire a nd a brown wire [...]

38 FEATURES In st ru men t at io n Gauge Cleanin g 1. W ipe the gauge f ac e as neede d using a clean cloth and a mild soap and wat er sol ut io n. W i pe dry w it h clean , s oft cl ot h. 2. Clean the back side of the ga uge using a clean cloth and a mild soap an d water s ol uti on . Do not rem ove th e elect rical co nnect ors or protec tive rub[...]

1 2 4 3 5 39 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Independe nt Front S uspens ion (IFS ) Brea k in the suspe nsion for a bout 150 miles (240 km) be fore making any f ine-tuning a djustments. Settings will vary f rom rider to rider , depending on ride r we ight, vehicle spe ed, riding style, and trail conditions. W e rec ommend st art[...]

40 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents W ARNING Always v erif y ski alignment bef ore making adjust ments t o t he IF S. See page 104 to check alignment . I f t he sk is are m isaligned, see y our dealer , as t he camber adjust ment may also be affect ed. The tension a t which the shoc k coil spring is set is calle d spring preloa d[...]

41 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Shoc k Dam ping Adjustments to the compre ssion stif fn ess of MPV S elec t shocks can be made by turning the adjustme nt screw ( + ) located near the ba se of the shock. This adjustme nt is the e asie st to per for m and it should be conside re d first. The f actor y setting for this shock is [...]

42 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Front S hock S pr ing Pr el oad Incr ea sing spring pre load will incre ase ski-to-ground press ure. Decreasi ng sp rin g prel oad wi ll d ecrease ski-to-gr ound pressure . When adjusting, be sure the springs on both the lef t and right sides of the mac hine are a t the same adjustme nt. A=L o [...]

43 THE PE RFECT FIT F AST M -10 Rear Suspension Adjustm ents The M-1 0 suspension has be en de signed to be ve ry sensitive to rider weight. Changes in ride r weight of 25 lbs. (1 1 kg) or more might requir e appropr iate c hanges in settings. The following infor mation has been c ompiled to a ssist you in tuning your M-10 suspe nsion to its maximu[...]

44 THE PE RFECT FIT F AST M -10 Rear Suspension Adjustm ents Sta tic S ag and Ride H eight S ettings FRA Posi tion The FRA se tting is the prima ry re ar suspe nsion adjustme nt. It will have the MOST effect on the rear su spen si on p erforman ce. T o adju st t he FRA: 1. Refer to the initial se t-up r efe re nce cha rt on pa ge 47 to de termine t[...]

45 THE PE RFECT FIT F AST M -10 Rear Suspension Adjustm ents Sta tic S ag and Ride H eight S ettings Rear Spr ing Prelo ad If FRA position alone does not allow the setup of the proper a mount of sag, t he cen ter ret ain er of t he rear t rack sh ock can be rep laced wit h optional retaine rs to adjust the preload an d change the sag. See your Po l[...]

46 THE PE RFECT FIT F AST M -10 Rear Suspension Adjustm ents Sta tic S ag and Ride H eight S ettings Ski Pressur e Ski pre ssure is se t at the fac tory to de liver the optimum bala nce betwee n ride and handling. If a rider pre fer s more ski pre ssure for improved ste er ing per forma nce , adjustments ca n be ma de to the f ront limiter str ap a[...]

47 THE PE RFECT FIT F AST M -10 Rear Suspension Adjustm ents Sta tic S ag and Ride H eight S ettings Ski Pressur e 4. There are al so two front a rm mounting holes in the slide rail th at can adju st s ki pressure . The lower hol e (A) in creases sk i pressur e while the upper hol e (B ) decreas es sk i p ress ure. NOT E: By design, the BIASED COUP[...]

48 THE PE RFECT FIT Handlebar Adjustm ents Handlebar Position Use the RIDER SELECT fea ture to adjust handlebar position. See page 28. Handl ebar A ngle Follow these steps to adjust handleba r angle at the handleb ar block. 1. R emove the handle bar cove r (A) to expose the handleba r and the four adjuste r block bolts (B). 2. Using a 7/16 ″ wren[...]

49 THE PE RFECT FIT Accessor ies Pol aris o ff ers a wi de range of accesso ries for your snowmobi le to help make each ri de mo re enj oyab le. NOT E: T he acces sory tet her s witc h is available f or all m odels. Or der PN 2870668. Use only Pol aris part s and accesso ries on your Pol aris snowmobi le. Use of unap prov ed part s and acces sori e[...]

50 THE PE RFECT FIT T raction P roducts Studs Befor e equipping your machine w ith traction produc ts, be aware of the laws in your a rea perta ining to the use of trac tion products. Use only Polaris tr ac tion products on your snowmobile . T rack warranti es are v oid if track damag e or fai lure res ul ts from im pro per or exc essive stud insta[...]

51 THE PE RFECT FIT T raction P roducts n Carbide Skags A skag i s a repl aceable bar at tached to t he underside of the ski to assi st in turning the snowmobile and to pre vent ski wea r ca used by c ontac t with roads and other ba re ter rain. Use c arbide ska gs with studded track s to h elp m ain tai n pro per vehi cl e steeri ng an d cont rol [...]

52 PRE -RIDE IN SPECTI ON S Pre - Ride Ch ecklis t Inspec t all ite ms on the c hec klist for pr oper opera tion or c ondition before each use o f th e sn owm obi le. Pro cedures are ou tlined on the referenced pages . Look for a checkm ark ( n ) on the re fere nced pa ges to locate the pre -ride inspe ction items. I t e m S e e P a g e Item S ee P[...]

53 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine W ARNING Worn, damaged, or malf unct ioning component s may c ause serious injury or death. B efor e st art ing the engine, chec k all component s t o be sur e of pr oper operat ion. Read a nd Under stand Y our Ow ner ’ s Manual Read the Owner ’ s Manual c ompletely and r efe r to it oft[...]

54 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Brakes Always ch eck th e following items fo r proper opera tion befor e starting the engine. Brake L ever T ravel Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1. 3 cm). A smaller d istance indic ate s low brake fluid leve l or air in the hydraulic[...]

4 3 1 2 55 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Par k Brake Lever Lock Use the park brake le ver lock only when you want the machine to remai n st ati onary ; for exam pl e, wh en parked o n an in cli ne for a perio d of five minutes or less. 1. B rake Lev er 2. P ark B rake Lev er Lock 3. Master Cylinder Rese rvoir / Cover 4. F[...]

56 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Steering S ystem Manually tur n the skis comple tely to the r ight and to the lef t. If any dif fic ulty is encounte re d, remove a ny ice a nd snow build-up tha t may be obstructing the stee ring linkage . n T rack W ARNING Oper ating t he snowmobile wit h a damaged t rac k incr eases t h[...]

57 PRE -RIDE IN SPECTI ON S Star t the E ngine and Check n Engine St op Switc h: Che ck the auxilia ry shut-of f switch f or proper opera tion. Push the switch down to stop the engine. Pull it up to allow r esta rting. n Ignit ion Swit c h: Make sur e the engine stops when the ignition switch is turned to OFF . n T ether S witch : If your machine h[...]

58 OPERATION Star ting the E ngine W ARNING Befor e st art ing the engine, always ref er t o all saf et y warnings pertaining t o snowm obile operat ion. Nev er st art y our snowm obile without chec king all com ponents to be s ure of proper operat ion. See Check Bef ore St art ing t he Engine beginning on page 53. Do not depress the throttle until[...]

59 OPERATION Slide Rail and T rack Cooling CAUTION Inadequat e cooling and lubric ation will lead t o over heating of t he slide rail and t rac k, r esult ing in premat ure wear and f ailure. Reduce speeds and fr equently drive int o f resh s now to allow adequate cooling and polis hing of t he slide r ail and tr ack surf aces. Avoid operat ing on [...]

60 OPERATION Engine B r eak -In Oil Injection System Alwa ys che ck an d fill the oil ta nk when r ef ueling. Mainta in the oil level at the bottom of the filler nec k. See page 61. CAUTION Serious engine damage can oc cur wit hout the pr oper lubric ation. Check t he oil tank level of t en during t he fir st tank of f uel. If t he oil level doesn?[...]

61 OPERATION Oil n Low Oil Level The low oil indic ator light will a lert the opera tor if the oil level is low . Add oil before fur ther opera tion of the snowmobile. S ee page 60 for oil rec ommenda tions. CAUTION Operat ing t he snowmobile wit hout adequat e engine lubricat ion can res ult in s erious engine dam age. A lways add oil when t he lo[...]

62 OPERATION Fuel W ARNING Gasoline is highly f lamm able and explosiv e under cer tain conditi ons. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always r efuel out doors or in a well- vent ilated ar ea. S Always tur n off t he engine befor e ref ueling. S Do not over fill t he t ank. Do not fill t he t ank neck . S Do not s[...]

63 OPERATION Fuel For peak per forma nce, Polaris rec ommends the use of 91 octane or higher fue l. Although 87 octa ne fuel is usable, some engine perf ormanc e will be lost and fue l economy will decr ease . Do not use fuel l ower th an 87 oct ane. CAUTION Operat ing with obs truct ed fuel syst ems will result in serious engine damage. Perfor m m[...]

64 OPERATION T rack W arm - Up W ARNING A loose t rac k or f lying debr is could c ause ser ious injury or deat h. Stand c lear of t he fr ont of t he machine and t he mov ing tr ack. Never hold t he snowmobile up or st and behind it while warming up the track. Do no t use excessive thro ttle during w arm-up o r when the t rack is f ree- hanging. U[...]

65 OPERATION n Engine Stop S wi tch Push down on the engine stop switch (A) to ground out the ignition and stop the e ngine quickly . Pull the switch up to the ON position to allow r estar ting. n Throttle S afety Switch The throttle saf ety switc h is designed to stop the engine w hene ver a ll pressur e is remove d from the throttle leve r and th[...]

66 OPERATION Throttle Lever W ARNING An impr operly f unct ioning thr ott le lever may cause er rat ic machine behavior and loss of c ontr ol, whic h could res ult in serious injur y or death. I f t he throt t le lever does not work pr operly , DO NOT st art t he engine. If the engine stops abr uptly when the throttle le ver is relea sed: 1. T urn [...]

67 OPERATION Em er gency Stoppi ng The following cha rt lists methods for stopping the snowmobile in the even t of an emer genc y . See page 65 for more infor mation about the engine stop sw itch a nd throttle sa fe ty switch. SYSTEM WHA T IT DOES THR OTTLE CONDI TI O N Igni ti on Swit ch Int err upt s igni ti on cir cuit All Brake Sl ows jackshaf [...]

68 OPERATION Electr onic Rever se (PE RC t ) Electr onic reve rse will activa te only if the engine RP M is below 4000. W ARNING Im proper r evers e operat ion, ev en at low s peeds, may c ause loss of cont rol, r esult ing in serious injury or death. Damage will occ ur to t he chaincas e or t ransm ission if s hift ing is at tem pted when t he eng[...]

69 OPERATION Daily Storage At th e end of each ride, p ark the sno wmo bi le o n a l evel su rface and support it at the rear with an appropr iate tra ck stand. The trac k should be suspende d appr oximately 4 ″ (10 cm) of f the ground. Remove the key and cove r the mach in e. T owing W ARNING Object s t owed wit h a rope have no br aking power a[...]

70 MAINTENANCE Em ission C ontr ol Infor m ation Any qu ali fied rep air sh op o r qual ifi ed pers on may m ai ntai n, rep lace, o r repa ir the emission contr ol device s or systems on your snowmobile. Em ission Cont rol Label Y our snowmobile is equippe d at the time of sale with an emission control inf ormation ( ECI) labe l and a f ac tory-ins[...]

71 MAINTENANCE Em ission C ontr ol Infor m ation Owner ’ s Responsibilities Plea se rea d the Snowmobile Engine Emissions Limited W ar ranty on page 123, and read the mainte nance se ction of your owner ’ s manual. Y ou are r esponsible f or ensuring that the specif ied maintena nce is perf orme d, including the emission- - re lated ma intena n[...]

72 MAINTENANCE Polar is Recom m ended Maintenance Pr ogr am T o ensure many trouble-free miles of snowmobiling e njoyment, follow rec ommende d regula r maintena nce a nd perfor m service c hec ks as outlined in this manua l. Recor d mainte nanc e and se rvic e in the Maintena nce L og beginning on page 125. The rec ommende d maintenanc e sche dule[...]

73 MAINTENANCE Per iodic Maintenance Inter val T able The following char t is a guide based on ave rage r iding conditions. Y ou may ne ed to incr ease fre quenc y based on r iding conditions. When ins pect i on rev eals t he need for rep lacem ent part s, al way s us e gen ui ne Polaris pa rts, ava ilable from your Polaris de aler . See Frequency [...]

74 MAINTENANCE Per iodic Maintenance Inter val T able See Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season BRAKES Hose Rou tin g -- I I I I Hos e Condition -- I I I I Fluid Leak s -- I I I I Brak e Pads 88 I I I I Brake Disc -- I I I I Parking Brakes 55 I I I I Brak e Sy s tem 53, 88 I Brak[...]

75 MAINTENANCE Per iodic Maintenance Inter val T able See Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season CHASSIS Sk i T oe A lignment -- I I I Sus pension Mounting Bolts -- I I I I I Steering F astener s -- I I I I I Rear Sus pens ion Fas teners -- I I I I I Sus pension S hoc k O il -- I [...]

L L L L 76 MAINTENANCE Lubri cation Front S uspe nsion Lubrica te the steer ing post U-joint with engine f ogging oil at the interv als outlined in the maintena nce c harts beginning on page 73. Lubrica te the U-joint after seaso nal s to rage as well as befor e seasona l storage. See page 1 1 1 for the part number s of Polaris products. The front [...]

L L 77 MAINTENANCE Lubri cation Driveshaft Bear ing Injec t grea se into the f itting on the speedome ter sensor housing until grea se pur ges from the seal on the inside of the tunnel. This should take a pproxima tely two pumps. Do not use more than four pumps. Throttl e Cable Lubric ate the thro ttle cab le lightly with grea se or oil. W ith the [...]

A B C 78 MAINTENANCE Lubri cation n Chaincase Oil Check the cha inca se oil le vel a t the interv als outlined in the maintena nce c harts beginning on page 73. The sight glass (A) is locat ed o n t he l ower rear o f the cha inca se. Mainta in the o il level a t or slightly below the ce nter of the sight glass (B). Change the chain case o il after[...]

D 79 MAINTENANCE Lubri cation Chaincase Oil Oil Chan ge 1. Position the vehic le on a level surface. 2. Remove the drain plug (D) and dr ain the oil into a dr ain pan. Allow the oil t o drain comple tely 3. Install a new sealing washe r on the drain plug. NOT E: T he sealing sur fac es on t he drain plug and t he oil tank should be clean and f ree [...]

80 MAINTENANCE Spar k Pl ugs A new e ngine c an ca use te mporar y spark plug f ouling due to the prese rvative adde d during the asse mbly proc ess. A void prolonge d idle speed s, which cause plug fouling and c arboniz ation. Change the spark plugs e very 2000- 2500 miles (3200- 4000 km). CAUTION Using non-r ecomm ended spark plugs can r esult in[...]

81 MAINTENANCE Spar k Pl ugs Spark plug c ondition is indicative of engine opera tion. The spar k plug firing end c ondition should be r ead a fter the engine has bee n war med up and t he veh icl e has been d riv en at hi gh er speed s. Imm edi atel y check th e spark p lug fo r correct col or . W ARNING A hot exhaust syst em and engine can cause [...]

L 82 MAINTENANCE Intake Filter The intake foa m filte r ( + ) limits snow ingestion into the intake system. Whe n opera ting in loose powder snow , check the foam filte r periodic ally to r emove any accum ul at ion o f snow . Fuel Injector s All fuel injec tor ser vice must be perf ormed by a n authoriz ed Polar is dealer . Do no t att em pt t o c[...]

L 83 MAINTENANCE Oil Filter Inspec t oil line c ondition at 1000 miles (1600 km) . The oil filte r ( + ) should be change d annually or eve ry 1000 miles (1600 km). The oil filter is locat ed o n t he l eft s id e of t he bulkhead be hind the drive clu tch . Have your dea ler perf orm the filter c hange a nd bleeding opera tion. NOT E: T he direct [...]

84 MAINTENANCE Exhaust S ystem Check the e xhaust system for wea r or damage a t approximate ly 2000 miles (3200 km) . T o inspect, allow the engine a nd exha ust system to cool comple tely . Ope n the hood and inspe ct the muf fler and pipe s for cracks or dam age. Ch eck for weak or m is si ng ret ain in g spri ng s or damper /support gr ommets. [...]

85 MAINTENANCE Cooling System Coola nt High T em per atur e Indicator Li ght The high te mpera ture indicator light is controlle d by a switc h in the ECU. If th e engi ne co ol ant r eaches a cert ain t emperat ure, t he s wit ch comple tes a circuit tha t turns the light on. If you must drive your mach ine afte r the high temperatur e indica tor [...]

86 MAINTENANCE Cooling System Bleeding the Cooling System Use of a non-standa rd pressur e cap will not allow the recover y system to fun cti on p roperl y . If the press ure cap need s repl acemen t, co ntact your dealer f or the corr ect part. W ARNING Steam and hot liquids will caus e serious burns to y our sk in. Neve r bleed the co oli ng syst[...]

A B 87 MAINTENANCE Drive Chain T ension Chec k drive c hain te nsion wee kly and befo re each lon g tri p. T o ob tai n correct chai n t ens ion : 1. Rotate the driven clutc h counter clockwise to move all chai n sl ack to t he ten si on er sid e. Lock the brake le ver lock, or have an assista nt hold the brake leve r firmly . 2. Loosen the adjuste[...]

88 MAINTENANCE Br akes n Hydraulic Br ake Inspection Inspec t the brake le ver reserve b efore each u se o f the snowmobile. Firmly depress the brake lever a nd measure the clearan ce betw een t he l ever and handle bar grip. This dis t ance, cal led brake l ever rese rve ( A), should be no less than 1/2 ″ (1.3 cm). Brak e pads m ust be r eplaced[...]

89 MAINTENANCE Br akes Br ake C ompone nts 1. B rake C ali per 2. Brake Disc 3. Backing Plate 4. Br ake P ad M ateri al (Rep lace when th ick - ness is le ss than 1/16 ″ /1.5mm). Excessive Lever T ravel Hydraulic br ake s are self- adjusting, but i f exces si ve br ake pad clearan ce develops (se e page 88), bring the machi ne t o an aut hori zed[...]

90 MAINTENANCE Br akes Br ake Fl uid W ARNING Aft er opening a bot t le of br ake f luid, alway s disc ard any unus ed port ion. Nev er st ore or use a part ial bot tle. Brake f luid is hygros copic, meaning it rapidly absor bs mois tur e from t he air . The m oistur e causes t he boiling tem perat ure of the br ake f luid to drop, which can lead t[...]

91 MAINTENANCE Br akes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spongy brake le ver a ction. Bleed the system befor e opera ting the snowmobile. W ARNING Oper ating t he vehicle wit h a spongy brak e lever c an result in loss of br akes, which c ould cause an ac cident and lead to s erious injury or death. N[...]

B A C 92 MAINTENANCE Lights NOT E: Do not t ouch a halogen bulb with bar e finger s. Oil fr om sk in leaves a r esidue, c ausing a hot spot t hat will s hort en the lif e of t he lamp. I f f ingers do touc h the bulb, clean it wit h an alcohol-m oistened t owel. Rem ovi ng Hal ogen Bul bs 1. Remove the plenum covering from the hea dlight assembly .[...]

93 MAINTENANCE Lights T aillig ht/Brakelight Replacement 700 Classic 1. Open t he rear st orage compa rtme nt. 2. Reach i nt o t he com partm ent and l ocat e t he so cket assembly a bove the door opening. 3. T urn the socket counter clockwise 1/4 turn . 4. Carefully pull the socket asse mbly awa y fr om the taillight. 5. Replace the bulb and re in[...]

A 94 MAINTENANCE Clutch S ystem W ARNING If you bec ome aware of higher t han norm al clut ch engagement or an unusual vibr ation or shif t pat t ern, see your dealer im mediat ely . Do not oper ate t he machine unt il repair s have been m ade. All clut ch m aintenanc e and repairs must be perf orm ed by an author ized Polaris dealer. Any unauthor [...]

+ 95 MAINTENANCE Clutch S ystem n Dr ive B elt C ondition Periodic ally c hec k the condition a nd tension of the drive belt, and always car ry a spare . Inspect the belt for signs of excessive wea r: fra yed edge s, missing cogs, cra cks and e xce ssive loosene ss. Replac e the belt if any of these conditions exist. For improve d drive- awa y duri[...]

96 MAINTENANCE Clutch S ystem Drive Belt Installation 1. Drop the drive belt over the drive c lutch a nd pull back the sl ack. NOT E: T o ens ure sat isf act ory belt life, inst all belt s so t hey operat e in the s ame direct ion of r otat ion by positioning t he identif icat ion numbers so that you c an read t hem. If required, separ ate t he she[...]

A B A .010 ″ -.030 ″ (.25- .75mm) 97 MAINTENANCE Clutch S ystem n Drive B elt Deflection Measu re bel t defl ecti on wi t h bot h clut ches at res t and i n th eir ful l neutra l position. Place a straight edge on the belt (A) and apply downwa rd pre ssure while measur ing at point B. This measur ement should be 1 1/4” (3.2 cm). Dr ive B elt [...]

98 MAINTENANCE T ool Ki t A too l ki t i s in clu ded wi th each m achi ne for em ergency and rou ti ne maintena nce . Always kee p the tool kit with the snowmobile. Fall T une -Up For maximum perfo rmanc e, arr ange for a f all servic e tune-u p with your Po lari s deal er . His exp erienced an d trai ned s ervi ce techn ici an wil l k eep your ma[...]

A 99 MAINTENANCE T rack Maintenance T rack Inspection W ARNING Brok en tr ack r ods can c ause a rot at ing tr ack t o com e off t he machine, which c ould cause s erious injur y or deat h. Never operat e with a damaged t rac k. Never rot ate a dam aged tr ack under power . 1. Using a hoist, safely lift and support the rear of the snowmobile of f t[...]

A 100 MAINTENANCE T rack Maintenance n T rack Alignment Periodic ally che ck tha t the tra ck is ce nter ed a nd running eve nly on the sl id e rail s. Mi sal ig nm ent wil l caus e excess i ve wear t o t he t rack and slide ra il. 1. S afe ly support the rear of the mac hine with the trac k off the ground. 2. S tart the engine an d apply a small a[...]

101 MAINTENANCE T rack Maintenance W ARNING Moving par ts can cut and cr ush body part s. When perf orming t he check s and adjust ment s rec omm ended on the f ollowing pages, st ay clear of all mov ing parts. Nev er perf orm t rack m easurem ent or adjust ment s wit h the engine r unning. T rack T ensio n T rack a djustment is critic al for prope[...]

102 MAINTENANCE T rack Maintenance T rack T ensio n 4. Ch eck for sp ecifi ed sl ack (A) between t he wear su rface of the track cli p and t he pl ast ic sl id er . R efer to t he T rack T ensi on Dat a Ch art on page 101. I f t he tr ac k nee ds adjust m ent : 5. Loosen the re ar idler sha ft bolt (B). 6. Loosen the locknuts (C). 7. T ighten or lo[...]

+ + + + 103 MAINTENANCE Steer ing System Steering Inspection and Adjustment Each week, or b efore a long ri de, ch eck all s teeri ng s ys tem fas ten ers and ti gh ten i f necess ary .[...]

X Y 10 ″ 10 ″ 104 MAINTENANCE Steer ing System Sk i Ali gnme nt W ARNING Im proper ski alignment or adjust ment may caus e loss of steering contr ol, r esult ing in serious injury or deat h. Do not at tem pt t o change the s ki alignm ent or camber adjust ment . S ee your Polaris dealer. W ith the handle bar s in a straight a hea d position, an[...]

A 105 MAINTENANCE Steer ing System n Ski S kags W ARNING Worn skis and/ or skags will adver sely affec t handling. Loss of vehicle cont rol may r esult , causing ser ious injury or deat h. See your dealer ’ s st udding char t f or r ecomm ended skags . I f you install longer or m ore aggres sive c arbide sk ags t han the or iginal equipment , it [...]

A 7/16 ″ (1.1 cm) 106 MAINTENANCE Suspension Maintenance n Slider W ear Measur e slider thic kness at sever al points along the rail. Have your de aler re place the slide r whe n it’ s worn to the top of the we ar groove (A) . Do not operate the snowmobile if slider thickne ss measur es le ss than 7/16 ″ (1. 1 cm ) at any point.[...]

107 MAINTENANCE Suspension Maintenance n Pr e -R ide Suspension In spection Loose nuts and bolts c an re duce your snowmobile ’ s re liability an d cau se nee dless re pair s and down time . Before beginning a ny snowmobile tr ip, a visua l inspection will uncover potentia l proble ms. Chec k the following ite ms on a we ekly ba sis or bef ore an[...]

108 MAINTENANCE Extended S tor age Of f-se ason or exte nded storage of your snowmobile r equire s preve ntive measur es to a id against de terior ation and to pr olong the use ful life of many compone nts. See page 1 1 1 for the part number s of P olaris products. Cleaning and Preser vation Proper stor age sta rts with cle aning, washing, and wa x[...]

109 MAINTENANCE Extended S tor age Bearings Grea se the jacksha ft and drive shaf t clutch side bearings with Polaris Premium A ll-Sea son Gr ea se or a similar h igh quality gre ase to pre vent corros io n. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubrica te clutc h compone nts, excep t the driven c lu[...]

11 0 MAINTENANCE Extended S tor age Electr ical Connections Repl ace worn or frayed elect rical wi re and co nnect ors . B e su re wiri ng harne ss is properly sec ured a way fr om sharp e dges, steer ing linkage, moving parts, and hot exha ust parts. T ra ck and S uspensi on Modera te tr ack te nsion should be mainta ined during summe r stora ge. [...]

111 POLARIS PRODUCTS Part No. Descri pt io n Engine Lubr icant s 2870791 Fogging Oi l ( 12 oz. Aerosol) 2871098 Premi um 2- Cycle E ngine Oi l ( qt. ) 2871097 Premi um 2- Cycle E ngine Oi l ( gal. ) 2871240 Premi um 2- Cycle E ngine Oi l ( 2.5 gal . ) 2871721 Premi um Gol d Synt heti c 2-Cycl e Engine Oi l ( qt. ) 2871722 Premi um Gol d Synt heti c[...]

11 2 TROUBLE S HOOTIN G Engine T r oubleshooti ng CAUTIO N: Unless you have e xper ience and training in two-c ycle engine re pair , see your deale r if tec hnical proble ms arise. Proble m Proba ble Ca us e Solutio n Err a ti c e ngine oper a ti ng R P M d u r i n g Driv e clutch bin d in g S SEE YOUR DEALER. R P M d ur i ng acceleration or loa d [...]

11 3 TROUBLE S HOOTIN G Engine T r oubleshooti ng Proble m P roba ble Ca use Solu tion Noise i n drive system Broke n drive c lutc h com ponent s S SEE YOUR DEALER. Bearin g failu re/ chain case, jack sh aft, or fr ont dri ve s ha ft S SEE YOUR DEALER. Driv e b elt su rface flat spot s S Insp ect an d replace as n eed ed . Driv e chain loo se S Ins[...]

11 4 TROUBLE S HOOTIN G Engine T r oubleshooti ng Proble m P roba ble Ca use Solu tion Engine t ur ns bu t fails to start Fau lty ig nitio n S In stall n ew sp ark plu g (s). If en g ine still fails to start, ch eck for sp ark . If th ere’ s no spar k, SEE YOUR DEALER. No fue l to e ngi ne S Ch eck the fu el tan k lev el an d fill with correct fu[...]

11 5 TROUBLE S HOOTIN G M-10 Suspensi on T roubleshooti ng Proble m Solution (pe rfor m only one c hange a t a time ) Rear su sp en sio n bo tto ms to o easily S Increase F R A p o sitio n (see p ag e 4 4 ). S Ins t al l a ppropr i a te opt i onal c e nte r ret a ine r on re a r tr a ck shoc k (s e e pa ge 45). S Inc r e as e f ront t ra c k shoc k[...]

11 6 TROUBLE S HOOTIN G Belt T r oubleshooting Be lt W ea r/B urn D iagnos is Causes Solutions Driv ing at low RPM S Driv e at h ig her R P M. G ear th e m achin e d o wn . C h eck bel t de fl e c ti on. Insu fficient w arm-u p S W ar m the e ngi ne at l e as t f ive m inut e s. T ake the dr i ve be lt of f t he m ac hi ne i n e xtr e me l y col d [...]

11 7 WARRANTY Ser vic e And Warranty I nform ati on Obtaining Service and W arranty Assistance Read and unde rstand the ser vice da ta and the Polaris war ranty informa tion containe d in this manual. Contact your Polaris dea ler f or replacem ent part s, s ervi ce or warrant y . Y our deal er receiv es freq uent updates on c hange s, modifications[...]

11 8 WARRANTY Li mit e d W arra nt y Pola r is S al e s Inc . , 2100 Highwa y 55, Medi na , MN 55340, provi de s a ONE YEAR LIM - ITED W ARRANTY on all c ompone nts of t he Pola ris s nowmobi le a ga ins t de fe c ts i n ma te r ia l or wor kma nshi p. This w ar r ant y cove r s the pa r ts a nd la bor cha r ges f or re pa ir or replacem en t o f d[...]

11 9 WARRANTY Limita tions of warranti es a nd remedie s ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LI MITED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TI CU- LAR PURPOSE) ARE LIMI TED I N DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA NT IE S NO T S T A T ED IN T [...]

120 WARRANTY Conditions and Ex cl usi ons In or de r t o qua li f y for wa r ra nty , the pr oduc t m ust ha ve bee n pr ope rl y s et up a nd te ste d by a Po laris D ealer (if ap plicab le). F ailu re o f an y d ealer to perfo rm th e req u ired v eh icle P re - - De li ve ry Ins pe ct i on, per f orm a ll a ppl ic a ble s e rvi c e bull e t ins [...]

121 WARRANTY Pol ar is Se cond Y ear E ngine S er vice C ontr act Sec ond Y e ar Engi ne Ser vi ce Cont r ac t is s t anda r d on a ll e li gibl e ne w a nd unuse d snow mobil e s tha t we re Snow Che c ke d thr ough a n aut hor iz e d Pola r is de a le r duri ng t he Ma rc h/ Apr il Snow Chec k promot ion. The f re e Se c ond Y e ar Engi ne Se rvi[...]

122 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t f rom Pola r is [...]

123 WARRANTY Snow mobi le E ngine Em issions Lim ited W ar r anty Th is sno wm o bile eng in e emission s limited warran ty is in add itio n to the Po laris stand ard li mi te d warr a nty f or s nowmobi le s . Pola r is I ndus tr i es I nc . wa rr a nts t ha t the ne w engi ne , inc l uding al l pa rt s of it s e mi ss i on- cont r ol sys t e m, i[...]

124 WARRANTY Snow mobi le E ngine Em issions Lim ited W ar r anty Some st a te s do not al low li mi ta tions on how long a n impli e d wa rr a nty la s ts , s o the a bove limitatio n may n o t app ly if it is incon sisten t with the con tro lling state law . This limited war- ra nt y exc ludes fa i lur e s not ca used by a de fe c t i n mat e ri [...]

125 MAINTENANCE LOG Present thi s sect ion of your manual to your deal er each time your snowmobile is service d. This will provide you and future owner s with an accurate l og of m ain ten ance and serv ices p erform ed on t he snowmobile. DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS 150 mi. (240 km ) 500 mi. (800 km ) 1000 mi. (16[...]

126 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

127 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

128 INDEX A Accesso ries 4 9 .................... A v alan ch es 14 .................... B Bea r ings 109 ..................... Bef or e Sta r ti ng the Engine 53-56 ...... Bel t T r ouble s hooti ng 116 ........... Bleed in g th e Coo lin g Sy stem 86 ...... Bleed in g t he H y d raulic B rak e S ystem 91 Bra ke Compone nt s 89 .............. Brak[...]

129 INDEX I Ic e a nd Snow Buil d-up 15 ........... IFS 3 9 .......................... IFS Adj ust me nt Opt ions 39 .......... IFS C ompone nts 39 ................ Ina de qua te Snow Condit ions 18 ...... Inde pe nde nt Front Sus pe nsi on 39 ..... Ins t rum ent a ti on 30- 38 ............... Intak e F ilter 82 .................... Intak e S ilen [...]

130 INDEX T T aillig h t/Brak elig h t Rep lacemen t 9 3 ... T eth er S witch 57 .................. Th ro ttle Cab le 7 7 .................. Th ro ttle Lev er 6 6 .................. Th ro ttle Safety Sw itch 65 ........... T ool Ki t 98 ....................... T orque St op 97 ................... T owi ng 69 ....................... Track 22 , 11 0 [...]