Polaris 7427 C manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e p roudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excell ence for a ll[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2007 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design [...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own ers and drivers and illustrates the location of important identification numbers that should be recorded in the owner ’ s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 [...]

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5 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 th e snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our model may differ . Follow the maintenance program out[...]

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation. Snowmobile clubs and o ther orga[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation numbers and k ey number in the spaces provided. Remove the spare key and store it in a safe place. Y our 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. V[...]

8 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

9 SAFETY Operator Safety Follow the recommended mainte nance program outlin ed beginning on page 99 of this manual to ensure that all critical co mponents on the snowmobile are thoroughl y inspected by your dealer at specific mileage intervals. WAR N I N G Driving a snowmobile requires your full attenti on. DO NOT drink alcohol or use drugs or medi[...]

10 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. Stay Clear of Engine Never attempt adjustments w ith the engin e running. T urn of f the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then resta[...]

11 SAFETY Operator Safety Riding Position Operating a snowmobile requires sk ill and balance for proper control. Rider positions may vary with expe rience; 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 throt tle, brake and steering control. Surviv[...]

12 SAFETY Operator Safety Riding Apparel Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania[...]

13 SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only . A decal on t he console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles ar e designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for o[...]

14 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehi cle requires good judgement and physical skills. Cargo Overload T oo much weight on the rear of th e 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 carrie[...]

15 SAFETY Operator Safety Excessive Speed Always observe all state an d local laws governing snowmobile opera- tion and speed limits. Al ways be alert and pay attenti on to the trail ahead. If your speed is 40 MPH (64 km/h), your snowmob ile is traveling about 60 feet (18 m) per sec ond. If you look back fo r only two seconds, your snowmobile will [...]

16 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 disti[...]

17 SAFETY Operator Safety Avalanches Snowmobilers should always be prop erly trained and equipped before traveling in mountainous terrain: • T ake an av alanche cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don’t have to be snowmo[...]

18 SAFETY Operator Safety I ce and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. NOTE: If your sno wmobile is equipped with RIDER SELE[...]

19 SAFETY Operator Safety Driving on Slippery Surfaces Driving in Hilly T errain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you mu st cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and av oid possible rollover[...]

20 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer . Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter [...]

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled mo dels, coo ling for the engine, adequate snow cover is a requirement for operation of your snowmobile. Driving in too little snow will result in excessive we ar and damage to the slide rail, track and[...]

22 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the mos t docile condi- tions may become dangerous if oper ators drive improperly . If you ’re new to snowmobiling, acquaint your self with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend so[...]

23 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you determine when tem- peratures become da ngerous for riding. WIND CHILL CHART ( ° F) WIND CHILL CHART ( ° C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperatu[...]

24 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this ma nual differ from the decals on your snow mobile, always read and follow the instructions of the de[...]

25 SAFETY Safety Decals and Locations “No P assenger” Warning Snowmobiles designed for a single rider only have a warning decal on the left console: WARNING This vehi cle is desi gned for operator only . “NO P AS SENGER” P assenger Warning Snowmobiles designed for an operator and one passenger have a warning decal on the left console. For m[...]

26 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with el ectric reverse and will have this decal on th e console: WARNING Reverse operation, even at low speeds, can cause lo ss of control resulting in seriou s injury or death. T o avoid loss of control, always: • Look behind before and while backin g up. • Avoi[...]

27 SAFETY Safety Decals and Locations Operation W arning An operation warning decal is pres ent on the console of all Polaris snowmobiles: WARNING • T o avoid serious injury or death, read and understa nd all warnings and the Owner’s Manual befor e operat ion. If manual is missing, con- tact a Polaris dealer for a rep lacement. • This vehicle[...]

28 FEA TURES 1. Nosepan 2. Skis 3. F ront Bumper (do not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Storage Compartment or Cargo Bag 8. Operator Seat 9. Passenger Seat 10. Backrest 11. P assenger Grab Handle 12. Grab Handle He ater Switch 13. T aillights 14. Rear Bumper 15. Snow Flap 16. T r ack 17. Suspension[...]

29 FEA TURES 1. MFD Display 2. Mirrors 3. Rider Select t 4. Fu el Filler Cap 5. Handlebar 6. Hood Hold Down Straps 7. Hand lebar Grip Warmer Switch 8. Thum bwarmer Switch 9. Electr onic Reverse Button 10. MFD Control 11. Headlight Dimmer Switch 12. Parking Brake Lo ck 13. Brake Lever 14. Engine Stop Switch 15. Throt tle Control 16. M-10 ACE Suspens[...]

30 FEA TURES Backrest The backrest is adjustable for either operator or passenger use. See page 32 for passenger seat installation instructions. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- ward for passenger use. 3. Always tighten [...]

31 FEA TURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to raise the headlight beam. Radiator Compartment Access P anel The access panel is provided for cleaning debris from the radiator . Cargo Bag (T ouring) The cargo bag is secured to the rear of the tunnel with straps. The car[...]

32 FEA TURES T runk/P assenger Seat/Cargo Bag (Cruiser) The trunk cover is removable to allow installation of the passenger seat and cargo bag. The maximum weight capacity for the cargo car- rier is 30 lbs. (14 kg). Always secure cargo before operating. Do not exceed the carrier weight limit. Do not allow a passenger to sit on the seat back or the [...]

33 FEA TURES P assenger Grab Handle On some models the position of the passenger grab ha ndles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab handles. 2. Rep osition the grab handles to one of the three available posi- tions on the grab handle tube between the operator seat and the passenger sea[...]

34 FEA TURES RIDER SELECT Adjusta ble Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions. WAR N I N G If your snowmobile has five adjustme nt positions, do not remove t[...]

35 FEA TURES RIDER SELECT Adjusta ble Steering System Choosing the Best RIDER SELECT Position Position Riding Style 1 2 3 Relaxed T rail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding. 4 5 General T rail Riding, Boondockin g, Deep Snow Riding Rider weight is centered on the snowmo- bile, provi[...]

36 FEA TURES RIDER SELECT Adjusta ble Steering System 1. Stop the snowmobile. 2. Press the releas e button and move the handlebar forward or rearward to the desired position. WAR N I N G Attempting to adjust the handlebar positi on while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile[...]

37 FEA TURES Engine Management Sys tem Malfunction Indicator Lamp (MIL) Illuminated MIL The MIL (Check Engine Indicator) will illuminate when a problem with engine management system components is detected. 1. Turn the engine of f and restart it. If the light goes off, continued operation is permissible. 2. If the light illuminates again, determine [...]

38 FEA TURES Engine Management Sys tem T o protect the engine, the engine management system will limit engine RPM, vehicle speed or tu rbo boost (if equipped) if the f ollowing condi- tions are encountered. Under extr eme overheating conditions, the sys- tem will also stop the engine en tirely to prevent engine damage. V ehicle Speed is Limited Eng[...]

39 FEA TURES Engine Management Sys tem The engine manag ement system is pr ogrammed to alert the rider when coolant temperatures reach higher-t han-normal levels. The sys tem responds by taking the following sequential steps to alert the rider . 1. The High T emperature Indicator on the MFD will flash. T o cool the engine, drive the snowmob ile int[...]

40 FEA TURES Knock Sensor (T urbo Models) A knock sensor m onitors th e engine and responds to detonat ion by auto- matically reducing the engine timing and addin g fuel. This results in decreased engine RPM and performance. NOTE: Engine perfor mance will be reduced if fuel with a low er octane than 91 is used. See fuel re commendations on page 89.[...]

41 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 High T emp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Ind icator Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System V oltage Level (all models) and M-10[...]

42 FEA TURES Instrumentation MFD Settings The MFD control switch allows yo u to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specif ic instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off. If the engine is of f, [...]

43 FEA TURES Instrumentation MFD Settings Speedometer/T achometer The speedometer and tachometer can be view ed in either the analog or the digital display . If the analog disp lay is set to show speedometer read- ings, the digital screen will automati cally display the t achometer (option 1). If the analog is set to show th e tachometer , the digi[...]

44 FEA TURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and Hist ory . Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycl e through the program’ s screens. Performa [...]

45 FEA TURES Instrumentation MFD Digital Display Programs Performa nce Program T rip Settings T rip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank. The T rip F od[...]

46 FEA TURES Instrumentation MFD Digital Display Programs Performa nce Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4. When the hour starts flashing, press the SET switch once to advance one hour . NOTE: [...]

47 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Press and release the MODE button until the engine program screen is active. The default display for this scr een includes engin e hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temperature, air temperature (accessory) or altime[...]

48 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. NOTE: Press and hold the MODE switch for ten seconds to switch between stand ard and [...]

49 FEA TURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cy cle through the Maximum V ehicle Speed, Maximum Engine RPM and Se[...]

50 FEA TURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the [...]

51 FEA TURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder T o reset the r eminder at a new interval: 1. Enter th e History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for fiv e seconds, until the hours begin to flash. Immediately[...]

52 FEA TURES Instrumentation MFD Digital Display Programs M-10 ACE Suspension Adjustments (Cruiser) A switch on the console (above the ignition switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. See page 69 for instructions. MFD Battery Replacement Models equipped with the clock feature have a battery to power the clo[...]

53 FEA TURES Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the batte ry holder . Pull the battery out gently . NOTE: The battery will not come out of t he holder unless the leading edge of the battery is raised. Hold the battery compartme[...]

54 THE PERFECT FIT IQ F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for approx imately 150 miles (24 0 km) before making any fine-tuning adju stments. Settings will vary from ri der to rider , depending on rider weight, vehicle speed, riding style, an d trail conditions. W e recommend starting with factor[...]

55 THE PERFECT FIT IQ F ront Suspension Adjustments F ront Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris de aler for assistance before attempt- ing to adjust preload. Increasing the spring preload too mu ch may adversely affect the han- dling of the snowmobile and the [...]

56 THE PERFECT FIT IQ F ront Suspension Adjustments Shock V alving The shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stif fness. F ront Springs The front spring rates can be adjusted by changing the nitrogen pressure. The upper chamber adjusts the main spring rate. The l[...]

57 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension design s and adjustments involv e a compromise, or tr[...]

58 THE PERFECT FIT IQ Rear Suspensi on Adjustments Initial Spring Preload Setting (Sag Method) T o set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may nee[...]

59 THE PERFECT FIT IQ Rear Suspensi on Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Different [...]

60 THE PERFECT FIT IQ Rear Suspensi on Adjustments Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension coupling, thes e torque arms could mo ve independently of each other . Rear su spension coupling links th e movement of the fr[...]

61 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ou nt of indepen- dent movement be tween the rear torque and the front torque arm. Adjusting the RRSS either all[...]

62 THE PERFECT FIT IQ Rear Suspensi on Adjustments W eight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scis sor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner- [...]

63 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments The M-10 suspension has been design ed to be very sensitive to rider weight. Changes in rider weigh t of 25 lbs. (1 1 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential [...]

64 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings 1. T o check sag, raise the rear bu mper until the suspension is fully extended (the rear shock will no t extend any further). Measure the distance from the g round to the bo ttom of the bumper (dimension X) as shown in the illustratio n. Record the measu[...]

65 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear su spension adjustment . It will have the MOST ef fect on the rear suspension performance. T o adjust the FRA: 1. Refer to the initial set-up refere nce chart (see page 68) to de termine the desired FRA pos[...]

66 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA position alo ne does not allow the setup of the proper amo unt of sag, the center retainer of the rear track shock can be repla ced with optional retainers to adjust the prel oad and change the sag. See your Polaris dealer for a[...]

67 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance be tween ride and handling. If a rider prefer s more ski pressure for improved steering performance, adjustments can be made to the front limite r strap and front arm mount. 1.[...]

68 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. The re are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole increases ski pressure while the upper hole decreases ski pressure. NOTE: By design, the BIASED COUPLE des ign of the M-10 suspensi[...]

69 THE PERFECT FIT F AST M-10 ACE Rear Suspension Adjustments MFD Suspension Adju stments (Cruiser) A switch on the console (above the ignition switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. NOTE: The engine must be running to make suspension adjust- ments with the MFD control switch . 1. Place the console rocker [...]

70 THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adju st handlebar position. See page 34. Use the following s teps to adjust handlebar angle at the handleba r block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Usin g a 7/16" wrench, loosen the four nuts on the bottom of th[...]

71 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury t[...]

72 THE PERFECT FIT T raction Products Studs Before equipping your snowmobile wi th traction products, be awa re of the laws in your area pertaini ng to the use of traction products. Use only Polaris traction prod ucts on your snowmo bile. T rack warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installation[...]

73 THE PERFECT FIT T raction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain prop er vehicle steering and control. See page 145. If your s[...]

74 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures 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 P age Drive Belt Condi tion 135 Steering System 7[...]

75 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of prop er operation. Read and Understan d Y our Owner's Manual Read the Owner's Manual completely and refer to it[...]

76 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile p rotects the operator from mov ing parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that th e hood straps ar e in good condition a[...]

77 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items fo r proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 " (1.3 cm). A smaller distance indicates low brake fluid leve l or air in the hydraulic system. Refer to t[...]

78 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Use the parking brak e lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a pe riod of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Rese rvoir/Cover 4. Fluid Level Indicator[...]

79 PRE-RIDE INSPECTIONS Before Starting the Engine n T rack Inspection NOTE: T rack damage or failure caused by o peration on ice or poor lubrica tion conditions voids the track warranty . WAR N I N G Operating the snowmo bile with a damaged track increases the possibility of track failure, which could cause loss of control re sulting in serious in[...]

80 PRE-RIDE INSPECTIONS Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems. Check the follow- ing items on a weekly basis or before any long trip. It[...]

81 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine S top Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when th e ignition switch is turned to OF F . n Lighting Check the headlight (hig h and low beam), t[...]

82 PRE-RIDE INSPECTIONS n Tip-Over Inspections In the event of a tip-over or rollover, check the oil level before operating the snowmobile. NOTE: In the event of a tip-over or rol lov er , the engine will stop . T o restart the engine, turn the key to the OFF position, then restart. CA UTION F ailure to check the oil after a tip-over can result in [...]

83 OPERA TION F uel Safety WAR N I N G Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution whenever h andling 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 s[...]

84 OPERA TION Break-In P eriod The break-in period for your new Po laris snowmobile is the first 500 miles (800 km) of operation. No sing le action on your part is as impor- tant as following the procedures for a prope r break-in. Careful treatment of a new engine and drive components will result in more ef ficient per- formance and longer life for[...]

85 OPERA TION Starting the Engine 1. Turn the key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. Do not apply throttle when startin g the engine unless extremely cold temperatures (below -15 ° F/-26 ° C) prevent the engine from start- ing. NOTE: Under these conditi ons, attempt to st art the engine with out using t[...]

86 OPERA TION Emergency Starting If the battery is too weak to start th e engine, and a batte ry charger is not available, the engine can be starte d using jumper cables and a charged battery from another ve hicle. Carefully read and follow the instructions on the following pages. NOTE: If a car or truck batte ry will be used to jump start the sno [...]

87 OPERA TION Emergency Starting 1. Always wear eye pr otection when jump starting your vehicle. 2. Kee p bystanders away from the vehicles. 3. Perform the emergenc y starting procedure in a well-ventilated area. 4. Position the vehicles close enough for the jumper cables to reach easily between the batteries, but do not allow the vehicles to touch[...]

88 OPERA TION Emergency Starting 12. Make sure that the engine st op switch is in the UP position. 13. Attempt to start the vehicle. 14. If the engine does not turn o ver (crank over), wait 30 to 60 sec onds and attempt to start the engine agai n. If th e engine does not start, wait another 1 to 2 minutes and atte mpt to start the engine again. 15.[...]

89 OPERA TION Fu e l For peak performance, Po laris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel econ omy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor e than 10% ethanol (including E85) . Fu e l L e v e l The fuel symbol and [...]

90 OPERA TION T rack W arm-Up WAR N I N G A loose track or flying debris could ca us e serious injury or de ath. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand beh ind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging. Be sure the rear[...]

91 OPERA TION T rack W arm-Up Follow these steps to ensure proper warm-up of the engin e, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper . The trac k should be approximately 4" (10 cm) of f the ground. 2. Start the engine and allow it to warm up two to three minutes. 3. Depr[...]

92 OPERA TION n Engine Stop Switch Push down on the engine stop switch to ground out the ig nition and stop the engine quickly . Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is design ed to limit engine speed to 2400 RPM whenever all pressure is remo ved from the throttle lever and [...]

93 OPERA TION n Throttle Lever If the engine speed limits at 2400 RPM when the throttle lever is released: 1. Turn the ignition switch to OFF . 2. V isually inspect the throttle cabl e and throttle body to determine what caused the safety switch to activate. 3. T est the throttle lever by compr essing and releasing it several times. The lever and c[...]

94 OPERA TION Electronic Reverse (PERC 4 t ) Electronic reve rse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum vehicle speed wh en oper- ating in reverse will be app roximately 12 MPH (19 km/h). Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmob[...]

95 OPERA TION Electronic Reverse (PERC 4 t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button fo r one second and release. The light on the instrument panel will shut of f. 3. Apply the throttle slowly to make sure the transmission is in for- ward. n Emergency Stoppi ng The following chart li[...]

96 OPERA TION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and support it at the rear with an appropriate track stand. The track should be susp ended approximately 4" (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g Do not use the fr ont bumper to pull or dr ag the snowmobile. The [...]

97 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control device s or systems on your snowmobile. Emission Control Label Y our snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa-[...]

98 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty on page 166, and read th e maintenance section of your o wner's manual. Y ou are responsible for ensuring that the specified maintenance is per- formed, including the emission-rela ted maintenance outlined in [...]

99 MAINTENANCE P olaris Recommended Mainte nance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 168. The recommended maintenance schedul e on your snowmobi[...]

100 MAINTENANCE P eriodic Maintenance Interval T able O = Perform Servic e X = Replace DAIL Y or PRE-RIDE INITIAL L Y Miles (km) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Stop Switch 81 T est for proper operat ion. Do not operate if switches fail, see your dealer for ser- vice. O [...]

101 MAINTENANCE P eriodic Maintenance Interval T able O = Perform Servic e X = Replace DAIL Y or PRE-RIDE INITIAL L Y Miles (km) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Coolant Hoses -- Inspect, r eplace if worn or damaged OO O Heat Exchangers -- Inspect, r eplace if damaged OO O F uel[...]

102 MAINTENANCE P eriodic Maintenance Interval T able O = Perform Servic e X = Replace DAIL Y or PRE-RIDE INITIAL L Y Miles (km) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Mounts -- Inspect, replace if worn or damaged OO Spark Plugs 117 Inspect condition/gap, replace as needed OO E[...]

103 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance T able beginning on page 100. Always change the oil filter whenever changi ng oil. See page 151 fo r the part numbers of Polaris products. Performance Synthetic 4-Stroke (PS-4) Oil Polaris recommends the use of Perfo rmance Synthe[...]

104 MAINTENANCE Engine Oil n Oil Level Check NOTE: Read the entire oil check procedure before checking the o il level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. T o obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant tem- perature mu[...]

105 MAINTENANCE Engine Oil n Oil Level Check NOTE: The oil level in the oil bottle may drain bel ow the level of the dipstick if the engine has not run for more than a week. If you're not sure if there is oil in the system, you must firs t check to make sure oil is in the sys- tem before checking the oil level. Perform the “Oil in System Che[...]

106 MAINTENANCE Engine Oil n Oil Level Check 8. Maintain the oil level in the safe operati ng range, between the upper and lower marks on the dip- stick. If the level is low , add the recommended oil in small increments, about 2 ounc es (60 ml), and recheck the level. NOTE: If the level is low , or when changing the oil, add only enough oil to brin[...]

107 MAINTENANCE Engine Oil Oil in System Check 1. Position the vehicle on a level su rface. Start the engine and allow it to idle 3-5 seconds (no more than 5 seconds). T urn the engine off. 2. Remove the dipstick. Clean the di pstick with a clean shop towel and reinstall it, screwing it in completely . Remove the dipstick and ver- ify that oil is p[...]

108 MAINTENANCE Engine Oil Oil Change Always change the oil at the interv als outlined in the Periodic Mainte- nance T able be ginning on page 100. Clean th e foam oil breather eleme nt with each eng ine oil chang e. See page 1 12. Always use the recomme nded oil. Se e page 104, or see your Polaris dealer about oil change kits, whic h contain a new[...]

109 MAINTENANCE Engine Oil Oil Change 5. Remove the oil return hose from the oil tank. H ave an assistant place the end of the hose into a drain pan. 6. Disconnec t the 2-pin WHITE/RED and GREEN/WHITE starter motor solenoid control switch harn ess connector located near the battery . 7. Rotate the plug 90 degrees an d reinstall it with the WHITE/RE[...]

110 MAINTENANCE Engine Oil Oil Change 18. Remove the oil filter cap, then remove the oil filter . Inspect the o- ring and replace it if it's worn or d amaged. 19. Install a new filter, then reinstall the cap. T ighten the cap to 18.5 ft. lbs. (25 Nm). 20. Remove the jumper from the starter motor wiring harnes s. Recon- nect the solenoid and th[...]

111 MAINTENANCE Engine Oil Oil Change 26. Add additional oil to bring the le vel slightly above the lower mark (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. NOTE: Check the oil level often duri ng the fill procedure to avoid overfilling. If the filling and checking procedu[...]

112 MAINTENANCE n F oam Oil B reather Element The foam oil breather element abso rbs small amounts of liquid to pro- tect sensors within the intake system fro m damage due to oil ingestion. Check the element before each ride. Clean or replace the breather ele- ment at each engine oil change. Clea n the element if the snowmobile has been tipped on i[...]

113 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into th e fitting on the speed- ometer sensor housing until grease pur ges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. W ith the engine off, tu[...]

114 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 100 and before seasonal stora ge. When operating in heavy , wet snow conditions, lubr icate every 500 miles (800 km). Lack of lubrication will adverse[...]

115 MAINTENANCE Gearcase Oil n Gearcase Oil Check Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance T able beginning on page 100. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 151 for the part numbers of Polaris products. The dipstick is lo cated on the lower front side of the gearcas[...]

116 MAINTENANCE Gearcase Oil Gearcase Oil Change The drain plug is located on the bottom of the gearcase. NOTE: Polaris does not recommend tip- ping the snowmobile onto it's side for service. Any time the snowmo- bile is tipped onto it's left side, always check the oil level and clean the foam oil breather ele- ment. See page 112. 1. Posi[...]

117 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plug fouling and carbonization. • Use recommended spar k plugs with the proper gap. • Use only resistor -type spark plugs. • T orque spark pl ugs to 18-20 ft.[...]

118 MAINTENANCE Spark Plugs Normal Sp ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should no t be white. A white insulator tip in dicates overheating, cause[...]

119 MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose po wder snow , check the top of the foam filter periodically to remove any accumulation of snow . F uel Injectors All fuel injector service must be performed by an au thorized Polaris dealer . Do not attempt to clean or servic[...]

120 MAINTENANCE n Alternator Belt Inspection Inspect the alternator belt conditio n and tension before each ride. 1. Stop the engine. 2. Op en the hood. 3. Inspect the belt for wear , cracks or other damage. If the belt is worn or damaged, install a new belt. 4. Grasp the alternator belt and attempt to twist it. 5. If th e belt rotates 1/4 turn (90[...]

121 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance T able beginning on page 100. 1. Allow the engine and exha ust system to cool completely . 2. Op en the hood. 3. Inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or d amper/s[...]

122 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-gly col and distilled water . This mix ture provides protection agains t freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water[...]

123 MAINTENANCE Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are: • Coolant bottle or overflow tank • Filler neck • Pressure cap • Connecting hose s Always maintain the coolant level at the “COLD FILL” mark on the coo l- ant tank (when the engine is cold). C[...]

124 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. S top the snowmobile and a llow the engine to cool. Place snow on the coolers to help cool the engi ne. If coolant is low in the[...]

125 MAINTENANCE Cooling System Flushing the Cooling System T o ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and distilled water shou ld be added. Have your Polaris dealer perform this service. Bleeding the Cooling System Bleed the coo[...]

126 MAINTENANCE Cooling System Bleeding the Cooling System 3. Op en the hood. 4. Remove the coolant pressure cap carefully . 5. Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck. Leave the pressure cap off. 6. With the cap off, start the engine and allow it to idle. 7. Wi[...]

127 MAINTENANCE Cooling System Bleeding the Cooling System 9. While observing the bleed return and making sure the coolant level is visible in the filler neck, observe the engine temperature in the digital display . The temperature sh ould rise steadily , indicating that the system is bleeding properly . 10. If the temperature does not rise af ter [...]

128 MAINTENANCE Drive Chain T e nsion Check drive chain tension weekly and before each long trip. T o obtain correct chai n tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly . 2. Loosen the adjuster bolt jam nut. 3. Finger [...]

129 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 77. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximat ely 1/16" (1.5 mm). A kit is avail- able for replacing brake pads. See your dealer . Brake Components ?[...]

130 MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 151 for the part numbers of Polaris products. The brake fluid level can be seen through the fluid le vel indicator (a plastic sight glass) in the master cyl- inder reservoir . If the fluid is suffi- cient, th[...]

131 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as leve l as possi- ble. The reservoir must be in this position to minimize the possibility of air entering the s[...]

132 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leave s a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it wi th an alcohol-moistened towel. 1. Remove the plenum cov- ering from the headlight assembly . 2. Lift the rubber boo[...]

133 MAINTENANCE Electrical System R E LA Y LA BE L FUSE L ABEL ITEM POWERED ST ART SOLENOID REL A Y Ground side of start solenoid CHAS SIS REL A Y SP ARE 20A None ACCESSORY EMERGENCY SP ARE 30A Accessory plugs CHASSIS 30A High beams Low beams Handwarmers Thumbwa rmer T ail la mp Brake l amp Alternator coils EFI REL A Y EX. SENSOR GAUGE 20A REVERSE [...]

134 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment offset i s import ant for maintaining optimum perfor- mance.Please see your Polaris dea ler if you experience a de[...]

135 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and exce ssive looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 158. Fo[...]

136 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility , make sure t he clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave. 2. Turn the ignition key of f. W ait for the engine to come to a complete stop. 3. Lock the parking bra[...]

137 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: T o ensure satisfactory belt life, install belts so they opera te in the same direction of rotation b y positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in t[...]

138 MAINTENANCE T rack Replacement When replacing the track, always inst all a track having the lug size rec- ommended for your mo del. See your Polaris deale r . T rack Inspection 1. Using a hoist, safely lift and sup- port the rear of the snowmobile of f the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track a[...]

139 MAINTENANCE T rack Lubrication The slide rail requires adequate snow cover for suf ficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limite d lubrication, resulting in excessive wear . NOTE: T rack damage or failure caused by operation on ice or under other poor lubricatio[...]

140 MAINTENANCE T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments should be made only aft er the track is warmed up and limber . 1. Turn the engine off. 2. Lift the rear of the snowmo- bile and safely su pport it of f the ground. 3. Pla ce the recommended [...]

141 MAINTENANCE T rack T ension 4. Che ck for specified slack between th e wear surface of the track clip and the plastic rail sl ide. If the track needs adjustment: 5. Loosen the rea r idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjus ting screws as necessary to provide equal adjustment on bo th sides of the track. 8.[...]

142 MAINTENANCE n T rack Alignment Periodically check that the track is centered and running ev enly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly[...]

143 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fa stener s weekly and before a long r ide. T ighten any loose fasteners. + + + + +[...]

144 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with veh icle weight compressing the suspension, measure from the straight e dge of the skis at the center of the sk i mounting bolt. The measurement between the skis at point X sh ould be 1/8" to 1/4" (3-6 mm) greater than the measuremen[...]

145 MAINTENANCE Steering System n Ski Skags Check skags before each use of the snowmobile to ensu re positive steer- ing characteristics. Skags must be replaced when worn to half their orig- inal diameter . NOTE: Carbide skag s must be replaced if any abnormal w ear or chipping is found. Skag Replacement NOTE: Some models ar e equipped with single [...]

146 MAINTENANCE Battery Battery Removal 1. Remove the left side panel. 2. Disconnect the battery hold-down strap. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift th e battery out of the vehicle . Battery Installation When installing a new battery , make su re it's fully char [...]

147 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to maintain a full charge. NOTE: Battery [...]

148 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a voltmeter or multimeter . A fully charged battery will register 12.8 V or higher . 2. If the voltage is less than 12.8 vo lts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater . [...]

149 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 componen ts. See page 151 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chassi[...]

150 MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model. Electrical Connections Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured awa y from sharp edges, steering linkage, moving parts, and hot exhaust pa rts. T rack and Suspension Moderate track tensi[...]

151 POL ARIS PRODUCTS Part No. Descripti on Engine Lubrica nts 2874865 P erformance Synthetic 4 -Stroke (PS-4) Oil (qt.) 2874866 P erformance Synthetic 4 -Stroke (PS-4) Oil (gal.) 2876244 P erformance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 P erformance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.) Chaincase Lubric ants 2873105 Synthetic Chain[...]

152 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Speed, RPM or Boost is Limited Engine Doesn't T urn Over Probable Cause Solution Engine Manageme nt System RPM Reduction Mode is activated See causes on page 38. Jammed clutc h Check for t wis ted belt or broken spring. See your dealer . Jammed track Remo ve any fo reign objec[...]

153 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine T urns Over , F ails to Start Engine Backfires Probable Cause Solution Out of fuel Refuel. W ater is present in fuel See your dealer . Old or non-recommended fuel Replac e with fresh recommen ded fuel. Fouled or defective spark plugs Inspect plugs and replace if necessary . No spar[...]

154 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Runs Irregularl y , Stops or Loses Power Probable Cause Solution Engine Manageme nt System RPM Reduction Mode is activated See causes on page 38. Low battery voltage Rechar ge the battery to 12.8 VDC. W ater is present in fuel See your dealer . Poor quality or low octane fuel Re pl[...]

155 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Overheating Harsh Drive Clutch Engagement Drive Belt T urns Over Drive System Noise Probable Cause Solution Inadequate snow conditions S top and c ool the engine. Drive into snow frequently to prevent overheating. See page 21. Low coolant S top and cool the engine. Check the cool- [...]

156 TROUBLESHOOTING IQ Comfort Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 58). • Change torsion spring to stif fer optional spring (see your dealer). • Rotate RRSS to higher position (see page 62). Rides too stiff in rear • Check fo[...]

157 TROUBLESHOOTING M-10 Suspension T roubleshooting Problem Solution (P erform only one change at a time) Rear suspension bottoms too easily • Increase FRA position (see page 65). • Install appropriate opt ional center retain er on rear track shock (see page 66). • Increase front track shock coil spring preload by adding washers. • Revalve[...]

158 TROUBLESHOOTING Drive Belt W ear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- up W arm the engine at least five minutes. T ake the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from th e snow . T owing at low RPM Do not tow[...]

159 WA RRANTY Service And W arra nty 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 . Y our dealer receives frequent updates on changes, modifications and tips on snowm[...]

160 W ARRANTY Service And W arra nty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monitoring program is designed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the prop er law enforcement officials, the ow[...]

161 WA RRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Polaris snowmobile against defects in material or workmanshi p. This warranty covers the parts and labor charges for repair or replacement of d efective parts t hat are cove red by this warranty . [...]

162 W ARRANTY Limitations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some s[...]

163 WA RRANTY 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, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to d elivery ma[...]

164 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontract is standard on all el igible new and unused snow- mobiles that were Snow Checked through an au thorized Polaris dealer during the March/April Snow Check promot ion. Th e free Second Y ear E ngine Service Contract is honored by all authorized Pola ris s[...]

165 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y 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 [...]

166 W ARRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine emi ssions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries In c. warrants that at the time it is first purchased, thi s emissions-ce r tified snowmobile engine meets current U.S. Environmental Protection[...]

167 WA RRANTY Snowmobile Engine Emis sions Limited W arranty Some states do not allow lim itations on how long an implied warranty lasts, so the above limitation may not appl y if it is inconsistent with the controlling state la w . This limited warranty excludes failures not ca used by a defect in material or workmanship. This lim- ited warranty d[...]

168 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wi th an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi[...]

169 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

170 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

171 INDEX A Access Panel, Radi ator Compartm ent 31 Accessori es . . . . . . . . . . . . . . . . . . . . 71 Adjustabl e Steering System . . . . 34-36 Air Filter (Turbo)). . . . . . . . . . . . . . 120 Alternator Belt Inspec tion . . . . . . . . 120 Apparel . . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . .[...]

172 INDEX I Ice and Snow Build- up . . . . . . . . . . 18 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Instrumentation . . . . . . . . . . . . . . 41-53 Intake Filters . . . . . . . . . . . . . . . . . 119 Intake Silencer . . . . . . . . . . . . . . . . . 20 J-K Jump-Starting . . . . . . . . . . . . . . . . 86-88 Knock Sensor (Turbo M[...]

173 INDEX S Suspension Performa nce Tips . . . . . . 57 Suspension Set-up Chart, M-10 . . . . 68 Suspension, F ront . . . . . . . . . . . . . . . 54 Switch Stop Switch . . . . . . . . . . . . . . . . 92 Suspension Adjustment Switch 30 Throttle Safety S witch . . . . . . . 92 T Throttle Cable Lubric ation . . . . . . . 113 Throttle Leve r . . . . . [...]