Polaris 800 Dragon RMK 155/163 manual

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For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922332 Rev 01 Printed in USA P antone 425C[...]

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 death. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or oth[...]

The text is printed on 100% recycled with 40% post-consumer waste (PCW).[...]

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 fo[...]

2 POLARIS, THE W A Y OUT , PERC, DRAGON, IQ, RMK and ASSAUL T are regis- tered trademarks of Polaris Industries Inc. Copyright 2009 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 and quality of production compone[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own e rs 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 e y number in the spaces provided below . The key nu mber is stamped on the spare key . The number on the rubber -coated key is in the form of raised dots. Remove the spare key and store it in a safe place. An ignition key can be duplicated only[...]

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 safety alert symb ol indicates a potential personal injury ha zard. WA R N I N G A W ARNING indi cat[...]

9 SAFETY Operator Safety Follow the recommended mainte nance program outlin ed beginning on page 71 of this manual to ensure that all critical co mponents on the snowmobile are thoroughl y inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full atten tion. DO NOT drink alcohol or use drugs or medications befo[...]

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. W ARNING! Serious injuries may result if hands, feet, or clothing become en tangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmob[...]

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 throttle, brak e and steering control. W ARNI[...]

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 Disabled Operators Safe operation of this rid e r -active vehicle requires good judgement and physical skills. W ARNING! Operators with cognitive or physical disabilitie s have an increased risk of loss of control, wh ich could result i n serious injury or death. Do not allow disabled persons to operate this vehicle. Rider[...]

14 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[...]

15 SAFETY Operator Safety Avalanches Snowmobilers should always be properl y trained and equipped before traveling in mountainous terrain: • T ake an av alanche class • 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 snowmob[...]

16 SAFETY Operator Safety I ce and Snow Build-up W ARNING! Ice and snow build-up may in terf ere with the steering of you r snowmobile, resulting in serious injury or death. Ke ep t he underhood area free of snow and ice. 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 rig[...]

17 SAFETY Operator Safety Driving on Slippery Surfaces W ARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driv i ng on ice or hard- packed snow reduces steering and braking control, which may result in loss of control and serious inj ury or death. Slow down and use extra [...]

18 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 . NOTICE: Operation of the engine with the belt re moved may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer o[...]

19 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspe nsion and, on liquid cooled mo dels, coo ling for the engine, adequate snow cover is a requirement for op eration of your snowmobile. NOTICE: Driving in too little snow will resu lt in excessive wear and damage to the slide rail,[...]

20 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 som[...]

21 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 S peed 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 emperat[...]

22 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for your 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 dec[...]

23 SAFETY Safety Decals and Locations “No P assenger” Warning Snowmobiles design ed for only a single rider have a warning de cal on the console below the steering post. WARNING This vehi cle is designed for operator only . “NO P AS SENGER” T rack W arning The track warning decal is on the rear of the tunnel. WARNING Stay clear of track. Do[...]

24 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with electric reverse have a reve rse warning decal on th e console. WARNING Reverse operation, even at lo w speeds, can cause loss of contro l resulting in serious injury or death. T o avoid loss of control, always: • Look behind before and while backing up. • A[...]

25 SAFETY Safety Decals and Locations Operation W arnin g (continued from previous page) • Excessive speed, especially at night or with limited visibility , can result in insuffici ent time for you to react to terrain ch ange s, to avoid unexpected obstacles , or to stop safely . • Never consume alcoho l or drugs before or while operating this [...]

26 FEA TURES 16 1. Front Bumper (d o not use for pulling or dragging the snow- mobile) 2. Hood 3. Headlight 4. Windshield 5. Mountain Bar (if equipped) 6. Handlebar 7. Seat 8. T a illights 9. Rear Bumper 10. Snow Flap 11. T rack 12. Suspension 13. T unnel 14. Side P anel 15. Ski 16. Nosepan 1 2 16 11 10 9 15 6 5 4 3 7 8 12 13 14[...]

27 FEA TURES 1. F uel Filler Cap 2. Ignition Switch 3. MFD (Multi-Function Display) 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Hood Hold-Down Straps 8. Brake Lever 9. Parking Brake 10. Handlebar Gr ip Warmer Switch 11. Thumbwarmer Switch 12. Electronic Reverse Bu tton 13. MFD Control 14. Headlight Dimmer Switch 1 2 8 3 4 [...]

28 FEA TURES Headlight Dimmer Switch Use the headlight dimmer switch to adj ust the headlights between high beam and low beam. Switch headlig hts to low beam when meeting oncoming traffic. Adjustable Headlights Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to raise the headlight beam. Adjustable Steering [...]

29 FEA TURES Detonation Elimination T echnology (DET) A detonation sensor monitors the engi ne and responds to detonatio n by automatically reducing the engine timin g and adding fuel. This results in decreased engine RPM and performance. Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power o[...]

30 FEA TURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil In dicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicat or 1 2 3 5 6 7 8 4[...]

31 FEA TURES Instrumentation Digital Display Identification Item 1 RPM or Speed Altitude (if equipp ed) Service Interval 2 Electrical System V oltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers pe r hour RPM - Engine crankshaft revolutions per minute 4 Air T emp (if equipped) Engine T e mp Degrees Celsius Degrees F a[...]

32 FEA TURES Instrumentation MFD Settings The MFD Control Switch allows you to set the MFD display to your preferences. The rocker switch h as a MODE button (top) and a SET but- ton (bottom). Specific in structions are outlined on the follo wing pages. Standard vs. Metric The MFD will display either standard or metric units of measurement. While vi[...]

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

34 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[...]

35 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Air T e mperature (accessory) The MFD displays actual air temperature. Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement. Altimeter (accessory) The rider can calibrate the altimeter for cur- rent atmospheric conditions[...]

36 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 following screens: maximum vehicle speed, maximum[...]

37 FEA TURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge log s the number of engin e hours accumulated between service reminders. When the logged hours reaches the desig- nated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in [...]

38 FEA TURES Instrumentation Gauge Cleaning 1. W ipe the gauge face as needed using a clean cloth and a mild soap and water solution. W ipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remo ve the electrical connecto rs or protective rubber boot. Do not spray the back[...]

39 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 rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions. W e recommend starting with factory[...]

40 THE PERFECT FIT IQ F ront Suspension Adjustments W ARNING! Always verify ski alignment before making adjustme nts to the IFS. See page 104 to check alignment. If the skis are misalig ned, see your dealer , as the camber adjustment may also be affected. Air Shocks W alker Evans air shocks can be adju sted for preload and valving. Please see your [...]

41 THE PERFECT FIT IQ F ront Suspension Adjustments Assault Shocks The tension at which the shock coil spring is set is called spring preload. For the best ride, the suspension should be adjusted to use th e full travel of the shocks with occasional light bottom- ing. After making spring adjustments, adjust shock clickers to control bot- toming. T [...]

42 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 des igns and adjustment s involve a compromis e, or t[...]

43 THE PERFECT FIT Rear Suspension 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 this measurement with no rider and with the rear suspension at full extension. TIP: The re ar bumper may need to be l[...]

44 THE PERFECT FIT Rear Suspension Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contac t your dealer for more information. The following information is provided only as a guidelin [...]

45 THE PERFECT FIT Rear Suspension Adjustments Shock Compres sion V alving Standard Rear T rack Shock The standard RMK rear track shock is an Arvin MPV Select shock th at allows for adjustments to the co mpression val ving. Adjustments are made by tu rning the adjustment screw located near the base of the shock. In hal f-turn increments: • T urn [...]

46 THE PERFECT FIT Handlebar Adjustments W ARNING! Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar . Such accessories could limit your ab ility to steer the vehicle and /or may contact the brake lever. This could lead to loss of control resulting in serious injury or death. Always be sure that ac[...]

47 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the hand lebar forward or rearward to the desired position. 3. T ighten the bolts. Handlebar Angle 1. Loosen the four bolts on the top of the ad juster block. If[...]

48 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 accessorie s on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

49 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 95 Steering System 53[...]

50 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. W ARNING! Operating the vehicle with worn , damaged, or malfunctioni ng components could result in ser[...]

51 PRE-RIDE INSPECTIONS Before Starting the Engine n Recoil Rope Inspect the recoil rope and handle fo r exces sive wear , and make sure the knot securing the rope inside the ha ndle is secure. If excessive wear is found, see your Polaris dealer for replacement. n Brakes Always check the following items fo r proper operation before starting the eng[...]

52 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Use the parking brake lever lock only when you want the sn ow- mobile to remain stationary; for example, when parked on an incline for a period of five min- utes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indica[...]

53 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left . If any dif- ficulty is encountered , remove any ice and snow build-up that may be obstructing the steering linkage. n T rack Inspection W ARNING! Operating the snowmo bile with a damaged track increases the possibili[...]

54 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[...]

55 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never en gage the starter when the en gine is running. Never start the engine with out checking all ve hicle components to be sure of proper operation. See Be fore Starting the Engine beginning on p[...]

56 OPERA TION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the tr ansmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the key to the ON position. Pull the engine stop switch up to the RUN position . CAUTION! T o avoid injury and/o[...]

57 OPERA TION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one p int of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure pr[...]

58 OPERA TION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. NOTICE: Serious engine damage can occur without the proper lu brication. Check the oil tank level often during t he first tank of fuel. If the oil level doesn't go down, contact your dealer immediately . Oil Recommendations This snowmobile is equip[...]

59 OPERA TION T rack W arm-Up W ARNING! A loose track or flying debris could cause serious injury or death. S tand clear of the front of the machi ne and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear suppo[...]

60 OPERA TION F uel Safety Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refuelin g. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or al[...]

61 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) . NOTICE: Operating with obstructed fue[...]

62 OPERA TION Oil n Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 58 for oi l recommendations. NOTICE: Operating the snowmo bile without adequate engine lubrication ca n result in serious engin[...]

63 OPERA TION n Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly . Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all pressure is removed from the throttle lever and the throttle cabl[...]

64 OPERA TION n Throttle Lever W ARNING! An improperly functioning thro ttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death . If the throttle lever does not work properly , DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition swi[...]

65 OPERA TION n Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 63 for more information about the engine stop switch. SYSTEM WHA T IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jacksha ft All Engine Stop Switch Interrupts ignition circ[...]

66 OPERA TION Electronic Reverse (PERC) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Da mage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed . • Shift to or from reverse only when the snowmobile is stopped and w[...]

67 OPERA TION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmobile is clear . 3. Push the reverse button on the left- hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation. TIP: A reve rse light on the in[...]

68 OPERA TION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g Do not use the front bump er to pull or drag the snowmobile. The fron[...]

69 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-[...]

70 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty , and read the maintenance section of your owner's manual. Y ou are respon si- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an auth orized Polaris dealer to[...]

71 MAINTENANCE P olaris Recommended Maintenance 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 125. The recommended maintenance schedul e on your snowmobil[...]

72 MAINTENANCE P eriodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer. I - Inspect (clean, adjust, tighten, l[...]

73 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e Fr e quency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- II II Brake Pads 89 II II Brake Disc -- II II Parking Brake 52 II II Brake System 51, 89 I Brake Fluid 91 R FUEL MANAG[...]

74 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I St[...]

75 MAINTENANCE Lubrication F ront Suspension The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Pr emium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 72 and before sea sonal storage. When operating in heavy , wet snow conditions, l[...]

76 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, tur[...]

77 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 71. The sight glass is located on th e lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass. Change the chaincase oil after the first 500 miles (800 km), th[...]

78 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely . 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. The sealing surfaces on the drain plug and the oil tank sho[...]

79 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher spe eds. Immediately check the spark plug for correct color . CAUTION! A hot exhaust system and engine can cause burns. Wear protective gl[...]

80 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 plu g fouling and carbon iza tion. Change the spark plugs every 2000-2500 miles (32 00-4000 km). NOTICE: Using non-recommended spark plugs can result in serious engi[...]

81 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 . NOTICE: Operating the snowmo bile with the intake filters removed may cause intake icing. The result will be poor fuel economy or[...]

82 MAINTENANCE F uel Injectors All fuel injector service must be performed by an au thorized Polaris dealer . Do not attempt to clean or service the fuel injectors. Fu e l P u m p All fuel pump service must be pe rformed by an authorized Polaris dealer . Do not attempt to service the fuel pump. F uel Filter See your Polaris dealer for replacement o[...]

83 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance T able beginning on page 71. CAUTION! Hot exhaust system parts can cause burns. Allow a dequate time for the exhaust system to cool. Never perfo rm this procedure with the engine running. Always allow the engine and exhaus[...]

84 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 against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water .[...]

85 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. If you must drive yo ur snow mobile after the high temperature indicator light has come on, drive slowly and stop frequently to a[...]

86 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when th e engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contac[...]

87 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance T able begin ning on page 72. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark. 2. Elevate the front [...]

88 MAINTENANCE Drive Chain T ension 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 ti[...]

89 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever travel before eac h use of the snowm obile. See page 51. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail- able for replacing brake pads. See your dealer . W ARNING! Brake failu[...]

90 MAINTENANCE Brakes Brake Components •B r a k e D i s c • Bleed Screw •B r a k e L i n e • Brake Caliper • Brake Pad Material - Replace when thickness is less than 1/16" (1.5mm). Excessive Lever T ravel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops (see page 89) bring the snow- mobile to an aut[...]

91 MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 1 10 for the part numbers of Polaris products. W ARNING! After opening a bottle of brake fluid, always discard an y unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meanin g it ra[...]

92 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. W ARNING! Operating the vehicle wi th a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never opera[...]

93 MAINTENANCE Lights Removing Halogen Bulbs Do not touch a halogen bulb with ba re fingers. Oil from skin leaves a residue, causing a hot spot that w ill shorten the life of the lamp. If fin- gers do touch the bu lb, clean it with an alcohol-moistened towel. 1. Remove the plenu m cov- ering from the headlight assembly . 2. Lift the rubber boot to [...]

94 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. W ARNING! If you become aware of higher th an normal clutch engagement or an unusual vibration or shift pattern, see your dealer immedia tely . Do not opera[...]

95 MAINTENANCE Clutch System n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Ot her belts may match the dimensions, but can drastically change the shif t pattern, resulting in poor perfor- mance. See [...]

96 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. 1. Stop the engine after operat ing in a forward motion. TIP: For easier accessibility , make sure th e clutch tool a[...]

97 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt and apply downward pressure while measuring at point A. This measurement should b e 1 1/4" (3.2 cm). Drive Belt Adjustment 1. Install the L-wrench into the open threa ded [...]

98 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 . NOTICE: Installing tracks with larger lugs on machines equip ped with coolers will result in damage to the cooler or tu nnel. Always install a track hav- ing the lug size recommende d for [...]

99 MAINTENANCE T rack Lubrication The slide rail needs snow for lubrication. Excessive wear indicate s insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear . W ARNING! Operating with in sufficient lubr ication between the rail slide and track guide clips can cause track failur[...]

100 MAINTENANCE T rack T ension W ARNING! Moving parts can cut a nd crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measur ement or adjustments with the engin e running. T rack tension is critical for maxi mum efficiency and performance. T rack tens[...]

101 MAINTENANCE T rack T ension If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. T ighten or loosen the track adjus ting screws a s necessary to provide equal adjustment on bo th sides of the track. 8. Repeat the measurement on the other side of the track. TIP: Check more freque ntly when the snowmobil[...]

102 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 t h e 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 slow[...]

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

104 MAINTENANCE Steering System Ski Alignment W ARNING! Improper ski alignment o r adjust ment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustmen t. See your Polaris deale r . W ith the handlebars in a straight a head position, and with vehicle weight compressing [...]

105 MAINTENANCE Steering System n Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressive carbide skags than the orig inal equipment, it may also be necessar[...]

106 MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or[...]

107 MAINTENANCE Matte Clear Coat Clea ning (if equipped) Matte finish products are prone to tr apping dirt, oils and other contami- nants. Polaris Industries recommends cleaning with warm water and a mild dish detergent. Use a soft spon ge to gently rub the surface and rinse with clean warm water . For stubborn stains such as grease or oil use a ci[...]

108 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings, spindle shafts, tie rod ends and cables as outlined in the Periodic Maintenance T a ble beginning on page 72. Bearings Grease the jacks haft and drive sha ft clutch side bearings w ith Polaris Premium All-Season Grease or a simi lar high quality grease to prevent corrosio[...]

109 MAINTENANCE Extended Storage 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 tension should be ma intained during summer storage. The machine sh ould be s[...]

110 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthet ic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.) 2877884 VES Gold Plus Synthetic 2-Cycle Engine Oil (2.5 gal.) 2877887 VE[...]

111 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEAL[...]

112 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jacks haft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or repl [...]

113 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel tank contains fuel. • Ice may be in the fuel line, filter o[...]

114 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Set static sag (see page 43). Adjust torsion spring blocks or install optional torsion spri ngs to achieve correct sag dimensions. Rides too stiff in rear • Check for bindi ng suspension components and grease all pivot points. • Set static [...]

115 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Driv e 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 ma chine in extremely cold weather and warm it up. Break machine loose fr[...]

116 W ARRANTY Service And W arra nty Information Obtaining Service and W a rranty 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 sno[...]

117 WA RRANTY 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[...]

118 W ARRANTY 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 Po laris snowmobile ag ainst defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of d efective parts that are cove red by this warranty .[...]

119 WA RRANTY 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 EXP RESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some [...]

120 W ARRANTY 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 veh i cle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to delivery m[...]

121 WA RRANTY 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 Polaris sn[...]

122 W ARRANTY 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 SELL ING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers[...]

123 WA RRANTY U.S.A. EP A Emissions Limited Warranty This emissions li mited warranty is in additi on to the Polaris standard limited warran ty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Environment[...]

124 W ARRANTY U.S.A. EP A Emissions Limited Warranty The exclusive remedy for breac h of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN TH IS LIMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF T[...]

125 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 wit h 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) 2000 mi[...]

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

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

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 48 Apparel for Riding . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Brake Components. . . . . . . . . . . . . . 90 Brake Fluid . . . . . . . . . . . . . . . . . . . 91 Brake Inspection . . . . . . . . . . . . . . . 89 Brake Lever Feel . . . . . . [...]

129 INDEX I Ice and Snow Build- up . . . . . . . . . . . 16 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Instrumentation . . . . . . . . . . . . . . 30-38 Intake Filters . . . . . . . . . . . . . . . . . . . 81 Intake Silencer . . . . . . . . . . . . . . . . . 18 L Lights . . . . . . . . . . . . . . . . . . . . . . . . 93 Limiter St[...]

130 INDEX S Survival Prep aration . . . . . . . . . . . . 11 Suspension Adjustments, Front . . 39-41 Suspension Adjustments, Rear . . 42-45 Suspension Inspe ction . . . . . . . . . . . 54 Suspension Lubrication, Front . . . . . 75 Suspension Lubrication, Rear . . . . . 75 Suspension Performa nce Tips . . . . . 42 Suspension, Front . . . . . . . . .[...]