Polaris FS Classic manual

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W ARNING W ARNING Read, understand, and foll ow all of the i nstructions and safety precautions i n this manual and on all product labels. Failure to foll ow the safety precauti ons could result in serious i njury or death. The engine exhaust from this product contains chemic als k nown to the S tate of Cali fornia to cause c ancer , birth defects [...]

1 WELC O ME Thank you f or pur cha sing a Polaris ve hicle , and we lcome to our wor ld-wide f amily of Polaris owne rs. W e pr oudly produce a n exc iting line of utility a nd re c re a tional pr oduc ts. S Snowmobiles S All- ter r ain ve hic le s (A TVs) S RANGER utility vehicle s S V ict or y mo to rcycl es W e be lie ve Polar is sets a standa r[...]

2 P OL AR IS an d P OL A RIS T H E W A Y O U T are reg istered trad emark s o f Po laris I ndus t r i e s I nc . RIDER SELECT is a tr a de mar k of Pola ri s Indus tr ie s Inc . Copyr ight 2005 Pol ar is Sa le s I nc. Al l i nfor mat ion c onta i ned wi thi n thi s publ ic a ti on is ba se d on the l a te st pr oduct i nfor ma ti on a t the t im e [...]

3 TABLE OF CO NTE NTS Intr oduction 5 ............................... This sec tion contains he lpful information f or owner s and driver s and illustra tes the loca tion of importa nt identific ation number s that should be re corde d in the owner ’ s manua l. Safety 8 ..................................... This sec tion desc ribes sa fe vehic le[...]

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5 INTRODUCTION Im portant N otes for O wner s and Dr iver s Afte r re ading t his manual, store it i n the snowmobile for conve nient re fer ence . It should rema in with th e snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual ar e gener al re presen tations. Y our model may dif fer . Follow the mainten[...]

6 INTRODUCTION Pr eser vation of the E nvironm ent Polar i s is committe d to supporting an e nvironmenta l educa tion ca mpaign. W e encoura ge state a nd provincia l governme nts ac ross the snowbelt to adopt r i gorous sa fety tra ining programs that e ncourage prote ction of our e nvironment, including wildlif e and vege tation. Snowmobile club[...]

7 INTRODUCTION V ehi cle Identifi cation Num ber s Rec ord your snowmobile’ s identif ication numbe rs and ke y number in th e sp aces pro vi ded. Rem ov e th e spare k ey and st ore i t i n a s afe pl ace. Y our ke y can be duplic ated only by ma ting a Polaris ke y blank with one of your e xisting keys, so if both keys a re lost, the ignition s[...]

8 SA FETY Operator S afety The f ollowing signal words and symbols a ppear thr oughout this manua l and on your vehic le. Y our safe ty is involved when the se words and symbols ar e used. Bec ome familia r with their mea nings befo re re ading the manual. The safet y alert s ymbol , on your vehicle or in this manual, alert s you t o the pot ent ia[...]

9 SA FETY Operator S afety Follow the r ecomme nded maintena nce pr ogram outlined be ginning on page 87 of this manua l to ensure that a ll critica l components on the snowmobile a re thoroughly inspec ted by your dea ler at spe cific mi l eage in terv als . W ARNING Driving a s nowmobile requir es your full at t ention. DO NO T dr ink alcohol or [...]

10 SA FETY Operator S afety Stay Clear of T rack Y our snowmobile is pr opelled by a re volving trac k that must be par tially exposed for p roper oper ation. W ARNING Serious injur ies may r esult if hands, f eet, or clot hing become entangled in t he t rack . B e alert when riding, and remain pr operly seat ed to s tay clear of t he tr ack. Never[...]

11 SA FETY Operator S afety Ri ding Posi tion Oper ating a snowmobile require s skill and balanc e for prope r contr ol. Rider positions may va ry with expe rienc e; but under ma ny conditions, the pr oper position is to be sea ted with both fe et on the r unning boar ds and both hands on the handle bar gr ips for prope r throttle, bra ke and stee [...]

12 SA FETY Operator S afety Ri ding Appar el Be p repared , b e warm an d b e comf ortable whe n riding. Be aware of t he weat her forecas t, es pecial l y th e windchill, a nd dre ss accord ing ly . S ee t he chart on page 22. W ARNING Avoid wearing loose clot hing or long scarves, whi ch can become ent angled in moving par ts and cause s erious i[...]

13 SA FETY Operator S afety Rider Capacity Dr iving 1-U p - Some P olar is snowmobiles are de signed for a single rid er on ly . A decal on t he console of these mode ls indicates single rider ope ration. Dr iving 2-U p - Some Polaris snowmobiles a re de signed for up to two rid ers. A d ecal o n t he hood of these models indica tes that the vehicl[...]

14 SA FETY Operator S afety Excessive S peed W ARNING High speed driv ing, es pecially at night , c ould result in ser ious injury or death. A lways r educe speed when dr iving at night or in inclement weat her . Always obser ve all state and loca l laws governing snowmobile oper ation and spe ed limits. Alwa ys be ale rt and pa y attention to the [...]

15 SA FETY Operator S afety Dr iver Aw areness Slow down when tra veling nea r pole s, po st s, or o th er ob st acles . B e especi al ly ale rt if you’re snowmobiling a fter dar k. Always be on the aler t for wire fe nces. Single strands are e specia lly dange rous, si nce t here m ay be a g reat d is tan ce betw een posts. Guy wir es on utility[...]

16 SA FETY Operator S afety A valan ches Snowmobilers should a lways be pr operly tra i ned a nd equipped be fore trave ling in mountainous te rrain: S T ake an aval anch e clas s S T ravel wi th ex peri enced peo pl e S T rave l on designate d trails S Mak e sure each perso n is eq ui pped wi th a shovel, probe and a valanche beacon. Y ou don’ t[...]

17 SA FETY Operator S afety Ice a nd Snow B uild - up W ARNING Ic e and snow build-up m ay int erf ere wit h the s teer ing of y our snowmobile, res ulting in s erious injur y or deat h. Keep t he underhood area f ree of snow and ic e. Bef ore dr iving, manua lly turn the skis to the le ft and right to be sure ice and snow ar e not interf ering wit[...]

18 SA FETY Operator S afety Dr ivin g on Slippery S u r f aces W ARNING Neve r attempt a n abrupt cha nge of dire ction when ope rating on sl ip pery s urfaces. P roceed sl owl y and u se ext ra cauti on . Driving on ic e or har d-pack ed snow reduc es st eering and br aking cont rol, whic h may result in loss of c ontr ol and ser ious injury or de[...]

19 SA FETY Operator S afety Drive Belt Do not o per ate t he engine w ith the dr ive belt r em oved. Any ser vicing that r equires opera tion without a be lt must be per formed by your de aler . Oper ation of the e ngine with the belt re moved may re sult in injury or da mage to the e ngine. Intake Silencer Do not ope rat e the engine w ith the int[...]

20 SA FETY Operator S afety Inade quate S now Conditions Since snow provides the only l ubric ation for the power slide suspension a nd, on liquid cooled models, cooling for the engine , ade quate snow cover is a re quire ment for oper ation of your snowmobile . Driving in too little snow will r esult in exc essive we ar and da m a ge to the slide [...]

21 SA FETY Operator S afety Dr ivi ng Respons ibly Ever y snowmobile handles dif f ere ntly , and e ven the most docile conditions ma y become da ngerous if ope rator s drive imprope rly . If you’re ne w to snowmobiling, acquain t yourself with the snowmobile and w ith what it will and w on’t do unde r var ious conditions. Even sea soned drive [...]

22 SA FETY Operator S afety Windchill/T emperature Char ts The f ollowing information is provide d to help you dete rmine whe n tempe rature s become dange rous for riding. WIND CHI LL CHART ( ° F) Wind Speed in MPH Act ual T hermom eter Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -1 5 -20 -25 -30 -35 -40 -4 5 Equivalent T em peratur e ( ° F)[...]

23 SA FETY Safety D ecals and Locations W arning decals have been placed on t he snowmobil e for your pro tect io n. R ead and fo ll ow th e ins tru cti on s of t he decal s and ot her warni ngs on t he s now mo bil e careful ly . If an y of t he d ecals depi ct ed in thi s manual di f fer from the decal s on your snowmobil e, always read and fo ll[...]

+ 24 SA FETY Safety D ecals and Locations “No Passenger” W arning Snowmobiles designed for a single ride r only have a warni ng decal on t he cons ol e below the stee ring post: Wa r mi n g This vehi cle i s designed f or oper ator only . “NO P ASSENGER” Passenger W arning Snowmobiles designe d for an ope rator a nd one passe nger have a wa[...]

25 SA FETY Safety D ecals and Locations Rever se W ar n ing Rever se operat ion, even at low speeds, may cause l oss of cont rol r esulti ng in ser ious i njur y or deat h. T o avoid l oss of cont rol , alw ays: S Look behind bef ore and w hil e backing. S A void shar p tur ns. S Shif t t o or f rom rever se only when st opped. S Apply t hrot tl e [...]

26 SA FETY Safety D ecals and Locations Operation W arning S T o avoid ser ious i njur y or deat h, read and under stand al l war nings and the O wner ’ s Manual befor e oper ati on. If t he manual is miss- ing, cont act a Polari s dealer for a repl acement . S This vehi cle i s capable of hi gh speeds. Bur ied object s or un- even te r r ain can[...]

27 FEATURE S 1. F ront B umper 2. Hood 3. Headlight 4. P assenger Lum bar Adjust er (T ouring) 5. Winds hield 6. Handlebar 7. O perat or Seat 8. P assenger S eat (T ouring) 9. P assenger G rab Handle 10. G rab Handle Heat er Swit ch (T ouring) 1 1. T runk Cov er or St orage Compart ment 12. T aillights 13. Rear Bum per 14. Snow F lap 15. T rac k 16[...]

28 FEATURE S 1. F uel F iller Cap 2. Rider S elect t 3. I gnit ion Switc h 4. Handlebar hook 5. B rake Lev er 6. M FD ( Mult i-F unction Dis play) 7. E ngine St op Switc h 8. T hrot t le Contr ol 9. Hood Hold Down S tr aps 10. Parkin g Brake 1 1. Handlebar G rip W ar mer Swit ch 12. T humbwarm er Switc h 13. Elec tr onic Rever se But t on 14. MF D [...]

+ 29 FEATURE S Passenger Seat (T our ing) The p ass eng er seat featu res an adj us tab le l um bar support. T o adjust for r ider comf ort, rota te the lumbar a djustment knob (A) . St orage C om partm ents T r unk (T ouring) Open t he t run k cov er (B) t o acces s t he rear s to rage co mpart m ent. The passe nger sea t and trunk cove r are remo[...]

+ + 30 FEATURE S Radiator C ompar tm ent Access P anel The acces s p anel ( + ) is provided for cl eanin g deb ris from t he ra diator . Car go Rack (S witchback) The max im um w eig ht capaci t y for th e car go rack ( + ) i s 15 lbs. (7 k g). Al ways s ecure cargo before o perat ing . Do n ot ex ceed the r ack we ight limit. Do not allow a passen[...]

31 FEATURE S RID ER S ELE CT Adjustable S teer ing System The RIDER SELEC T adjustable steer i ng system allows you to adjust the handle bar position to fit your style of riding. S ome models have five (5) a djustment positions. Other models have se ven (7) positions. W ARNING If y our snowmobile has five adjust ment posit ions, do not remov e the [...]

32 FEATURE S RID ER S ELE CT Adjustable S teer ing System Adj u st in g RI DER SELECT W ARNING At tem pting t o adjust t he handlebar posit ion while t he snowmobile is mov ing could res ult in l oss of cont rol and ser ious injur y or death. A lways s top t he snowm obile befor e att empt ing t o adjust the steerin g syst em. 1. Stop the snowmobil[...]

33 FEATURE S Engi ne Manageme nt System Malfunc tion Indicat or Lam p (MIL) The MIL (Che ck Engine Indica tor) will illuminate when the ECU dete cts a pr oblem with engine manage ment system c omponents. If this occ urs, see your de aler fo r service immediate ly . The MI L will blink in the eve nt that the ECU de tects an e rror with the turbo boo[...]

34 FEATURE S Engi ne Manageme nt System T o protec t the engine , t he engine manage ment system will limit e ngine RPM, vehicle spe ed or tur bo boost (FS T) if t he f ollowing conditions ar e encounter ed. V ehicle Speed is L im ited Cause Functi on Maxi mum Speed MPH (km/ h) Result Rev ers e is s elec ted Reverse 12 (19) Defec tiv e rollov er s [...]

35 FEATURE S Engi ne Manageme nt System E ngine Over heats (FS ) Indi cati on At V ehi cle Speed MPH (km/ h) At Engine Te m p ° F( ° C) Explanat ion Flas hing h l 0-31 (0- 50) 230 (1 10) Lamp flas hes w hen i g ov erheat lamp 32-46 (51- 74) 230-221 (1 10-105) p engine temperat ure e x c e e d s t a b l e v a l u e s 47-62 (75- 100) 221-212 (105- [...]

36 FEATURE S Detonati on Eli mi nation T echnology (D ET) (T urbo Model s) A de tonation se nsor monitors the engine and re sponds to detonation by automa tically r educing the engine timing a nd adding fue l. This results in d ecreased en gin e RP M and p erform ance. NOT E: E ngine perf ormanc e will be reduced if f uel with a lower oct ane than [...]

37 FEATURE S In st rume nt at io n MFD Com ponent Identific ation Item 1 Analog G auge 2 Digi tal Gauge 3 Check Engine I ndicat or 4 High T emp Indi cator 5 Brake I ndicat or 6 Rever se Indicat or 7 High Beam I ndicat or Digital Display Identification Item 1 RPM or Speed Alt it ude (i f equipped) Servi ce Int erval 2 Elect ri cal System V ol tage L[...]

38 FEATURE S In st rume nt at io n MFD Settings MFD settings ca n be made with the engine r unning or with the engine of f. If the e ngine is of f, make sure the stop switc h i s pre ssed down a nd turn the ignition key to the ST AR T position brie fly to activa te the gauge. The gauge will illumina t e for about 90 se conds. Use the MFD C ontrol S[...]

39 FEATURE S In st rume nt at io n MFD Digital Disp lay Pr og ram s Press the MODE button to cycle thr ough the three MFD progra m s: Per forma nce , Engine an d History . Eac h progra m will rema in in the display until another is sele cted. NOT E: T he analog will always dis play eit her MP H or engine RPM (whichev er set t ing is selec ted) rega[...]

40 FEATURE S In st rume nt at io n MFD Digital Disp lay Pr og ram s Performance P rogram Clo ck Setti ng 1. While in the CLOCK displa y , press and hold the SET button f or five sec onds. 2. Whe n the hour star ts flashing pre ss the SET switch once to advanc e one hour , or pr ess and hold the SET button to advanc e t he hour once eve ry 0.2 secon[...]

41 FEATURE S In st rume nt at io n MFD Digital Disp lay Pr og ram s Al tit ude (if e quipped) The r ider ca n ca librate the a ltimeter f or cur rent atmosphe ric conditions. Altimete r accuracy wi ll b e +/-3 00 ft . (91 m ) after adjustme nt. NOT E: P ress and hold t he MO DE s witc h for ten s econds t o swit ch between s tandar d and met ric un[...]

42 FEATURE S In st rume nt at io n MFD Digital Disp lay Pr og ram s History P rogram The History Pr ogra m automatic ally displa ys elec trica l system voltage leve l and fu el leve l. While in the Histor y mode, press the S ET button to vie w maximum vehic le speed, m a ximum engine rpm or the curr ent ser vice inte rval s e t t i n g . The gauge [...]

43 FEATURE S In st rume nt at io n MFD Digital Disp lay Pr og ram s Se rvic e Inte rv al R em inde r The gauge logs the number of engine hours betwee n ser vice reminde rs. When the logged hours reaches the designa ted ser vice inte rval (se t by the user ), the gauge provide s a reminder that ser vice is due. “SE rVCE” w ill flash in the odome[...]

44 FEATURE S In st rume nt at io n MFD Batter y Replacement If the c lock function of the MFD isn’ t worki ng p roperl y , repl ace th e batt ery . Rep lacem ent bat teri es are av ail abl e from your dea l er . 1. Remove the plenum from the under side of the hood. 2. Locate the bla ck battery com part ment (A). It h as a red wire a nd a brown wi[...]

45 FEATURE S In st rume nt at io n MFD Batter y Replacement 6. Insta l l a ne w batter y with fingers only . 7. Sea l the end of the batte ry compa rtment using high stre ngth double- sided tape be tween the two c ompartme nt halves or high stre ngth single-sided ta pe ar ound the outside of the compa rtment. 8. M ake su re th e tap ed seam of t he[...]

1 2 4 3 46 THE PE RFECT FIT IQ Fr ont S uspension Adj ustments Indepe ndent Front S uspensi on (IFS ) Bre ak in the suspe nsion for appr oximately 150 mile s (240 km) be fore making a ny fine- tuning adjustments. Settings will vary f rom rider to rider , depending on ride r weight, vehic le speed, riding style, and tra il conditions. W e re commend[...]

47 THE PE RFECT FIT IQ Fr ont S uspension Adj ustments S hock Dam ping Adjustme nts to t he c ompre ssion stiff ness of ArvinMe ritor MP V Selec t shocks ca n be made by turning the adjustme nt scr ew ( + ) lo cated n ear th e bas e of t he shock. This a djustment is the e asiest to per form and it should be c onsidered firs t. The f actor y s e tt[...]

48 THE PE RFECT FIT IQ Fr ont S uspension Adj ustments Shock V alving (Switchback) The shoc ks can be r evalve d if spring preloa d alone isn’ t suf ficient a nd fur ther adjustme nt is desired to c ontrol suspension stif fn ess. W ARNING Changing shock valving r equires s pecial t ools and a sound knowledge of mechanic al theor y , t ool use, an[...]

49 THE PE RFECT FIT Rear S uspension Adjustm ents Rider w eight, riding style , trail c onditions, and ve hicle spe ed all af fe ct suspension a ction. Each rear su spen si on can b e adju st ed to s ui t rid er preference and delive r exce llent perfor mance f or a given set of conditions. However , all suspension designs and adjustme nts involve [...]

50 THE PE RFECT FIT Switchback R ear S uspension Initi al Spr ing P rel oad Setting (S ag Method) T o set up the rear suspension torsion spring p reload, mea sure the distanc e betwee n the ground and r ear bum per . Thi s i s meas urem ent X . T ake this measur ement with no ride r and with the re ar suspension at f ull exte nsion. NOT E: T he rea[...]

51 THE PE RFECT FIT Switchback R ear S uspension Rear T orsion Spring T ension T o adjust rea r torsion spr ing tension, rota te the thre e-position c am using the engine spark plug tool. Dif fer ent rate torsion springs are a vailable if a fir mer ride is desired. Contact your dea ler for more infor mation. A. Sof t T ensio n - long end of c am to[...]

52 THE PE RFECT FIT Switchback R ear S uspension Rear T rack S h ock Compr essio n Damping A. T urn r ear tr ack shoc k screw clockwise to stif fe n compre ssion. B. T urn the rea r trac k shock knob clockwise for a sof ter ride . C. T urn the r ear tr ack shock knob counte r clockwise for a stif f er ride . B C A[...]

L 53 THE PE RFECT FIT Switchback R ear S uspension Rear S h ocks Whe n adjusting, we r ecomme nd that you turn the adjuster slightly , then te st ride. The re commende d setting for this shock is eight (8) clic ks counter - cloc kwise. FOX Ze ro Pro X C Shock The FOX Zer o P ro X C shock is standa rd on the Switchba ck model. T urn the adjustme nt [...]

54 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents The M- 10 suspension has be en designe d to be very se nsitive to ride r weight. Changes in rider weight of 25 lbs. (1 1 kg) or more might re quire appropr iate cha nges in settings. The following infor mation has bee n compiled to a ssist you in tuning your M-10 suspension to its maximu[...]

55 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents S tatic S ag and Ri de Height S ettings 3. Subtrac t Y from X and you will have the S AG se tting (X - Y = sag setting. Example: 21 - 17 = 4) . The c orrec t amount of SAG f or the F AST M-10 re ar suspension is 3- 4 i nche s (8-10 cm) . If the measur ed sag is incor rec t , adjust the F[...]

56 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents S tatic S ag and Ri de Height S ettings FRA Pos ition The FRA se tting is the prima ry r ear suspe nsion adjustme nt. It will have the MOST effect on th e rear s us pens io n perform ance. T o adju st t he FRA: 1. Refe r to the initial se t -up r efe renc e char t (loca ted unde r the ho[...]

57 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents S tatic S ag and Ri de Height S ettings Rear Sp ring Prelo a d If FRA position alone does not allow the setup of the proper amount of sag , t he cen ter ret ain er of t he rear t rack sh ock can be rep laced wi t h optional reta iners to adjust the pre load and change the sa g. See your [...]

58 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents S tatic S ag and Ri de Height S ettings Ski Pressu re Ski pre ssure is se t at the f actor y to delive r the optimum ba lance betwe en ride and handling. If a ride r prefe rs more ski pressure f or improve d steer ing perf ormanc e, adjustments c an be ma de to the fr ont limiter strap a[...]

59 THE PE RFECT FIT F AS T M-10 Rear S uspension Adjustm ents S tatic S ag and Ri de Height S ettings Ski Pressu re 4. Th ere are als o tw o front a rm mounting holes in the slide rail th at can adj ust s ki pressur e. The lower hol e (A) i ncreases sk i pre ssure while the upper ho le (B ) decreas es s ki p ress ure. NOT E: By desig n, the BIASED [...]

60 THE PE RFECT FIT Handlebar A djustments Use the RIDER SELEC T fea ture to adjust handleba r position. See page 31. Use the following steps t o adjust handle bar a ngle at the handle bar block. 1. Remove the handleba r cover (A) to expose the handle bar and the four a djuster block bolts (B). NOT E: I f equipped, rem ove the mount ain bar (C) . 2[...]

61 THE PE RFECT FIT Passenger Gr ab Handle A djustment (T our ing) On some T ouring models the position of the passe nger gra b handles c an be a djusted for rid er preference. T o m ake an adj us tm ent : 1. Unscre w and remove the knob asse mblies (A) tha t secur e the gra b handle s. 2. Reposition the gr ab handle s to one of the thre e availa b[...]

62 THE PE RFECT FIT T racti on Pr oducts S tuds Befor e equipping your snowmobile with trac tion products, be awa re of the laws in your are a pertaining to the use of trac tion produc ts. Use only Polar is traction p roducts on your snowmobile . T ra ck warrant ies are v oid if t rack d amage o r fail ure res ult s fro m i mp roper o r exc essive [...]

63 THE PE RFECT FIT T racti on Pr oducts n Car b ide Skags A skag i s a repl aceable bar at tached t o the undersi de of the s ki t o assi st in turning the snowmobile and to pre vent ski wea r cause d by contac t with roads and other ba re ter rain. Use ca rbide skags with studded track s t o help m ai nt ain p roper veh icl e st eering an d con t[...]

64 PRE -RID E INSPECT IO NS Pre - Ride Ch ecklist Inspe ct all ite ms on the c hecklist f or pr oper ope ration or condition before each us e of t he sn owm obi l e. Pro cedur es are ou tline d on the referenced pag es. Lo ok for a checkm ark ( n ) on the r efer enced pa ges to locate the pr e-ride inspe ction items. I t e m S e e P a g e Item S ee[...]

65 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine W ARNING Worn, dam aged, or malf unct ioning component s may caus e serious injury or deat h. Bef ore st art ing t he engine, c heck all component s t o be sur e of pr oper operat ion. Re ad and Under stand Y our O wner ’ s Manual Read the Owner ’ s Manual c ompletely and re fer t[...]

66 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine n Hood La tches The hood of the snowmobile protects the opera tor from moving parts as we ll as aiding in sound emissi on c ontrol and other func tions. Under no cir cumstances should your snowmobile be oper ated with the hood open or remove d. Always ensure tha t the hood straps are [...]

67 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine n Br akes Alway s check t he follow ing items for pr oper oper ation befor e starting the engine . Br ake Lever T ravel S queeze t he b rake l ever . It should move no c l oser to the ha ndgrip than 1/2 ″ (1. 3 cm). A smalle r distanc e indicate s low brake f luid level or air in th[...]

D C A B 68 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine n Par k Brake Lever Lock Use the park bra ke lever lock only when you want the snowmobile to remai n st ati on ary; fo r examp le, when p arked on an i ncl in e for a period of five minute s or less. A. Brak e Lever B. P ark B rake Lev er Lock C. Maste r Cylinder Reser voir / [...]

69 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine n T rack Inspection W ARNING Oper ating t he snowm obile with a dam aged tr ack inc reases the possibilit y of t rack f ailure, which c ould cause los s of cont rol result ing in serious injury or deat h. Alway s inspect t he trac k for damage bef ore using t he vehic le. Use of tr ac[...]

70 PRE -RID E INSPECT IO NS Check B efore S tar ting the E ngine n Suspension In spection Loose nuts a nd bolts can r educe your snowmobile’ s relia bility and ca use nee dless re pairs and dow n time. B e for e beginning a ny snowmobile trip, a visual inspe ction will unc over pote ntial proble ms. Chec k the following ite ms on a wee kly basis [...]

71 PRE -RID E INSPECT IO NS Check A fter S tar ting the Engine n Engine St op Sw itch Chec k the auxilia ry shut-of f sw itch for pr oper ope ration. Push the switch down to stop the e ngine. P ull it up to allow re starting. n Ignit ion Swit ch Make sur e the engine stops when the ignition switch is turned to OFF . n Light ing C hec k the he adlig[...]

72 PRE -RID E INSPECT IO NS n T ip -Over Inspections In the eve nt of a tip-over or rollove r , chec k the oil leve l befor e oper ating the snowmobile. CAUTION Failur e to c heck t he oil af ter a tip- over c an result in ser ious engine damage. Always check the oil lev el befor e operat ing a snowmobile t hat has t ipped over or rolled over . NOT[...]

73 OPERATION Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain condit ions. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always ref uel outdoor s or in a well- vent ilated ar ea. S Always tur n off t he engine befor e ref ueling. S Do not ov erf ill the t ank. Do not f ill the t ank nec k. S [...]

74 OPERATION Br eak - In P er iod The bre ak-in per iod for your new Polaris snowmobile is the first 500 miles ( 800 km) of oper ation. No single ac tion on your par t is as importa nt as following the proce dure s for a proper br eak- i n. Caref ul tre atment of a new engine a nd drive compone nts will result in more ef fic ient perfo rman ce and [...]

75 OPERATION Star ti ng the Engi ne W ARNING Bef ore st art ing t he engine, alway s ref er t o all saf et y warnings pert aining to s nowmobile operat ion. Never s tar t y our snowm obile without chec king all com ponents to be s ure of proper oper ation. See Check Bef ore S tar ting t he Engine beginning on page 65. Do not depress the throttle un[...]

76 OPERATION Em er gency Star ting If the batte ry is too wea k to start the e ngine, and a ba ttery c har ge r is not ava ilable, the e ngine ca n be starte d using jumper c ables a nd a charged bat tery from ano th er vehi cle. C areful ly read an d fol lo w the instruc tions below . W ARNING Im properly connect ing or dis connect ing jumper cabl[...]

77 OPERATION Em er gency Star ting 8. Pull back the re d plastic boot cove ring the positive termina l of the we ak batter y . Connect one end of the positive jumper c able to the positive ter minal of the wea k batter y . 9. Connec t the other end of the positive jumper c able to the positive ter minal of the cha r ged batter y . NOT E: M ake sur [...]

78 OPERATION T rack W ar m -Up W ARNING A loose t rac k or f lying debr is could c ause ser ious injury or deat h. St and clear of t he fr ont of t he machine and t he mov ing tr ack. Never hold t he snowm obile up or st and behind it while warming up the track. Do no t use excessi ve throttle du ring warm-u p or when the t rac k is f ree- hanging.[...]

79 OPERATION Fuel For peak pe rf ormance , P olar is rec ommends the use of 91 octane or higher f uel. Although 87 octa ne fuel is usable , some engine per formanc e will be lost a nd fuel e conomy will de crea se. Do not use fuel l ower t han 87 o ctan e. CAUTION Operat ing wit h obs tr ucted fuel syst ems will result in serious engine damage. Per[...]

80 OPERATION n Engi ne S top Sw itch Push down on the engine stop switc h ( L ) to gr ound out the ignition and stop the engine quickly . P ull the switc h up to t he RUN position to allow r estar ting. n Throttle S afety S witch The thr ottle saf ety switch is de signed to stop the e ngine when ever a ll pre ssure is remove d from the throttle le [...]

81 OPERATION n Throttle Lever W ARNING An impr operly f unct ioning t hrot tle lev er may cause er rat ic machine behav ior and loss of c ontr ol, whic h could res ult in serious injur y or death. I f t he throt t le lever does not work pr operly , DO NOT s tar t the engine. If the e ngine stops abruptly whe n the throttle leve r is rele ased: 1. T[...]

82 OPERATION Electr onic R everse (P ER C 4 t ) Elec tronic reve rse will activate only whe n the vehicle is stopped and engine speed is below 2500 R PM. Maximum e ngine spe ed when oper ating in reve rse will be 6000 RPM. W ARNING Im proper r ever se operat ion, ev en at low s peeds, may c ause los s of c ontr ol, r esult ing in serious injur y or[...]

83 OPERATION n Em er gency S topping The following cha rt lists methods for stopping the snowmobile in the eve nt of an emer ge ncy . S ee pa ge 80 for more infor mation about the engine stop switch a nd throttle sa fety switc h. SYSTEM WHA T IT DOE S THR OTTLE CONDI T IO N Igni ti on Swit ch Int err upts i gnit ion ci rcuit All Brake Sl ows jacksh[...]

84 OPERATION Daily Storage At t he end of each rid e, park t he snowmobile on a level surfa ce and suppor t it at the re ar with a n appr opriate tra ck stand. The tra ck should be suspende d appr oximately 4 ″ (10 cm) of f the ground. Remove the key an d cover the snowmobile. T owin g W ARNING Objec ts towed wit h a rope hav e no braking power a[...]

85 MAINTENANCE Em issi on Contr ol Infor m ation Any q uali fi ed repai r shop o r qual ifi ed pers on m ay mai nt ain , rep lace, or re pair the emission contr ol devic es or systems on your snowmobile. Em ission Con trol Label Y our snowmobile is equippe d at the time of sale with an emission contr ol i nfor mation (ECI) label and a fac tory-inst[...]

86 MAINTENANCE Em issi on Contr ol Infor m ation Owner ’ s Responsibilities Plea se rea d the Snowmobile Engine Emissions Limited W arr anty on page 147, and rea d the maintenanc e section of your owner ’ s manual. Y ou are r esponsible for ensur ing that the specifie d mainte nance is per forme d, i ncluding the emission- - rela ted mainte nan[...]

87 MAINTENANCE Polar is R ecomm ended Maintenance Pr ogr am T o ensure many trouble-free mile s of snowmobiling enjoyme nt, follow re commende d regula r maintena nce and per form ser vice c hecks as outlined in this ma nual. Recor d maintena nce a nd servic e in the Mainte nance L og beginning on page 149. The re commende d maintena nce sche dule [...]

88 MAINTENANCE Per iodic Maintenance Inter val T able D = Pe rform Se rvice " = Rep lace DAIL Y or PRE- RIDE INITIALL Y mi (km ) YEARL Y or EVERY mi (km ) Ite m Pg I n structi o ns (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine S top Swit ch 71 T est for proper operat ion. Do not o p e r a t e i f s w i t c h e s f a i l s e e y[...]

89 MAINTENANCE Per iodic Maintenance Inter val T able D =P e r f o r m " = Rep lace DAIL Y or PRE- RIDE INITIALL Y mi (km ) YEARL Y or EVERY mi (km ) Ite m Pg I n structi o ns (see referenced pages) 150 (240) 500 (800) 1500 (2400) Co ol ant H oses -- Inspec t, replac e if w orn or damaged D D D Heat Exch ang ers -- Ins pect , replace if damage[...]

90 MAINTENANCE Per iodic Maintenance Inter val T able D =P e r f o r m " = Rep lace DAIL Y or PRE- RIDE INITIALL Y mi (km ) YEARL Y or EVERY mi (km ) Ite m Pg I n structi o ns (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Mount s -- Inspec t, replac e if w orn or damaged D D Spa rk Plugs 102 I nspec t condit ion/gap, replac e a[...]

91 MAINTENANCE Engi ne Oil Alwa ys chec k and change the e ngine oil at t he inte rvals outlined in the P erio dic M ai nten ance T ab le b egi nning on page 88. Always cha nge the oil filter whe never c hanging oil. See pag e 133 for the part number s of Polaris pr oducts. Per formance S ynth etic 4 - S troke (PS - 4) Oil Polaris re commends the u[...]

92 MAINTENANCE Engi ne Oil n Oil Level Check NOT E: Read t he ent ire oil chec k proc edure bef ore chec king t he oil level. The o il l evel w il l ri se as eng in e tem perat ure i ncreas es. Th e oi l l evel will be lower when the engine is cold. T o obtain a proper oil level re ading, the snowmobile must b e on a l evel su rface, an d t he eng [...]

93 MAINTENANCE Engi ne Oil n Oil Level Check 6. Clea n the dipstick w ith a cle an shop towel a nd reinsta ll it, scre wing it in comple tely . 7. Remove the dipstic k and view the oil leve l. NOT E: T he oil level r eading will be accur ate f or only one t o t hree minut es af ter tur ning off t he engine. If t he oil check is n’t complet ed wit[...]

94 MAINTENANCE Engi ne Oil Oil Chan ge Alwa ys cha nge the oil at the interva ls outlined in the Periodic Mainte nance T able beginning on page 88. C lea n the foam oil breathe r elem ent wi th each en gi ne oi l ch ang e. See p age 9 7. Always use the rec ommended oil. S ee p age 91, or see your Polaris dea ler about oil cha nge kits, which c onta[...]

95 MAINTENANCE Engi ne Oil Oil Chan ge 9. Open th e hand leb ar cov er . Locat e th e con nect or wi th t he B R OWN and R ED/ WHITE wi res. C on nect t he B ROWN wi re from th e ju mp er harnes s t o t he B RO WN wire o n t he han dl ebar harn ess b y inser ting t he ha rness plug into the ha ndlebar wir ing harne s s conne ctor . 10. Open the fus[...]

96 MAINTENANCE Engi ne Oil Oil Chan ge 22. Make sur e the engine coola nt t empe rature is betwe en 145 and 160 degr ees F . (63-71 de gre es C ). If nec essar y , s tar t the engine and allow it to idle until the coola nt temper ature is within the spec ified range . 23. Remove the d ipstick from the oil tank. Clea n the dipstick with a cle an sho[...]

A B 97 MAINTENANCE Foam Oil Br eather E lem ent The f oam oil bre ather eleme nt absorbs sma ll amounts of liquid to prote ct sensors within the intake system fr om damage due to oil in ges ti on . C l ean or rep lace t he b reath er elem ent at each eng in e oi l cha nge. Clean the eleme nt if the snowmobile has bee n tipped on its lef t side thre[...]

+ + L L L L 98 MAINTENANCE Lubr ication Dr ivesh aft Bear ing Inje ct grea se into the fitting o n t he spee dometer sensor housing until grea se pur ges from the seal on the inside of t he tunnel. This should take a pproximate ly two pumps. Do not use more than four pumps. Thr ottle Cable Lubric ate the thro ttle ca ble lightly with gre ase or oil[...]

L L L L 99 MAINTENANCE Lubr ication M- 10 136 Rear Susp ension Switch back Rear Su spen sion L L L L L[...]

A B 100 MAINTENANCE Lubr ication n Gearcase Oil Ch eck an d chan ge t he g earcase oi l at the inte rvals outline d in the P erio dic M ai nten ance T ab le beginning on pa ge 88. Polar is rec ommends the use of Polaris Synthetic Chainc ase Lube. See page 133 for the par t numbers of Polaris produc ts. The dipstick (A ) is loc ated on the lo wer fr[...]

A 101 MAINTENANCE Lubr ication Gearcase Oil Oil Ch ange The dr ain plug (A) is locate d on the bo tt om o f t he gearcas e. NOT E: P olaris does not r ecomm end tipping t he snowm obile onto it’ s side for service . Any time the s nowmobile is t ipped ont o it’s left s ide, always c heck t he oil level and c lean the f oam oil breat her element[...]

102 MAINTENANCE Spar k P lugs A ne w engine c an ca use tempora ry spar k plug fouling due to the pre servative added dur ing t he a ssembly proc ess. A void prolonged idle spee ds, which ca use plug f ouling and ca rbonization. CAUTION Using non-r ecomm ended spark plugs can r esult in ser ious engine damage. A s park plug wit h a heat r ange too [...]

+ 103 MAINTENANCE Intake Filters The inta ke foam filte r limits snow ingestion into the intake system. When ope rating in loose powder snow , check the top of the foam filte r per iodically to r emove an y accum ul ati on of s now . Fuel Injector s All fuel inje ctor ser vice must be pe rforme d by an author ized Polar is deal er . Do no t at tem [...]

104 MAINTENANCE Alter nator Belt Inspection Inspe ct the alte rna tor belt c ondition and tension a t t he inte rvals outlined in the Periodic Mainte nance T able be ginning on page 88. 1. St op the engine . 2. Open the hood. 3. Ins pect t he belt f or wear , cracks o r ot her d amage. If the be l t is worn or dama ged, install a new belt. 4. Grasp[...]

105 MAINTENANCE Exhaust S ystem Chec k the exha ust system for we ar or dama ge at the interva ls outlined in the P e riodic Maintena nce T able beginning on page 88. W ARNING Hot exhaust system parts can c ause serious burns. A llow adequate t ime f or the ex haust syst em t o cool. N ever perf orm this procedur e with t he engine running. 1. Allo[...]

A 106 MAINTENANCE Cooling S ystem Cool ant The coola nt supplied in the system is a 60/40 mixture of ethyle ne-glyc ol and distille d water . This mixture pr ovides prote ction agains t freezing. C ontact your dealer i f greater protect io n is requi red. Use P remi um 6 0/ 40 ant i-freeze coo lan t, whi ch is al ready p remi xed an d ready t o use[...]

107 MAINTENANCE Cooling S ystem Cool ant Hi gh T em pera ture Indica tor Light The high temper ature indic ator light will illuminate whe n engine coola nt t empe rature become s too hot for saf e continue d operation of the engine . If you must drive your snowmobile afte r t he high tempe rature indic ator light has come on, drive slowly and stop [...]

108 MAINTENANCE Cooling S ystem Bleeding the Coolin g System W ARNING The engine exhaust f rom t his product cont ains chem icals known to c ause canc er , bir th def ect s or ot her r eproduct ive har m. Oper ate t his v ehicle only out doors or in well-v entilat ed areas . 1. Read the entir e coolant bleed proc edure be fore beg inning. After beg[...]

109 MAINTENANCE Cooling S ystem Bleeding the Coolin g System 8. W ith the engine idling, and while making sure tha t the level in the fille r neck re mains visible, observe the ble ed retur n. If the syste m is self -blee ding prope rly , coolant w ill be pumped out of this hole. NOT E: Coolant f low may be er rat ic (spit ting, m ist ing) for the [...]

A B 11 0 MAINTENANCE Drive C hain T ensio n Chec k drive c hain tension weekl y and befo re each lon g tri p. T o ob tai n correct ch ain tension: 1. Rotate the dr iven clutch counte rclockwise to move all chai n sl ack t o th e tens io ner side. Lock the brake le ver lo ck, or h ave an as si st ant ho ld the bra ke lever f irmly . 2. Loosen the ad[...]

111 MAINTENANCE Br akes n Hydraulic Br ake Insp ection Ins pect t he b rake l ever reserv e before each us e of t he sn owm ob il e. S ee page 67. Br ake pad s m us t be r eplaced when t he b rake pad mat eri al beco mes thinner t ha n t he ba cking pla te, approxima tely 1/16 ″ (1 . 5mm). A kit is ava ilable for re placing bra ke pads. S ee your[...]

11 2 MAINTENANCE Br akes Br ake Fl uid W ARNING Af ter opening a bott le of br ake f luid, alway s disc ard any unus ed port ion. Never s tor e or use a par tial bot t le. Brak e fluid is hygros copic, meaning it rapidly absorbs moist ure f rom the air . The m oist ure caus es t he boiling tem perat ure of t he brak e fluid t o drop, which can lead[...]

11 3 MAINTENANCE Br akes Bleeding th e Hydraulic Br ake System Air in t he hydra ulic brake syste m will cause spongy bra ke l e ver action. Bleed the system bef ore opera ting t he snowmobile. W ARNING Oper ating t he vehic le with a s pongy brak e lever c an result in loss of br akes, which c ould cause an ac cident and lead to s erious injury or[...]

B A C 11 4 MAINTENANCE Lights Re movi ng Haloge n Bul bs NOT E: Do not t ouch a halogen bulb wit h bare f ingers. O il f rom s kin leaves a r esidue, causing a hot spot t hat will s hort en the lif e of t he lamp. I f f ingers do touc h the bulb, clean it wit h an alcohol-m oist ened towel. 1. Remove the plenum cove ring fr om the hea dlight assemb[...]

11 5 MAINTENANCE Electr ical S ystem REL A Y LABE L FUSE LA BE L IT EM POWERED ST ART SOLENOID RELA Y Gr ound side of star t solenoi d SP ARE 20A None C H A S S I S ACCESSOR Y EMERGENCY SP ARE 30A Accessor y plugs CHASSIS R E L A Y High beam s REL A Y C H A S S I S Low beams CH A SSIS 3 0 A Handwarm ers 3 0 A Thumbwar mer T a il la mp Brake l amp A[...]

A 11 6 MAINTENANCE Clutch S ystem P eriod ical l y in sp ect cl ut ch sh eaves fo r dam age, wear or b elt resi du e. T o maintain optimum pe rfor m a nce, cle an with non- oil based c lea ner s such a s isopropyl alcohol. W ARNING If you bec ome aware of higher t han norm al clut ch engagement or an unusual vibr ation or shif t pat t ern, see your[...]

A B 11 7 MAINTENANCE Clutch S ystem n Dr ive B elt Condi tion Per iodically c heck the condition and te nsion of the dr ive belt, and always ca rry a spare . Inspect the belt for signs of excessive we ar: fr ayed edge s, missing cogs, cra cks and e xce ssive loosene ss. Replac e the belt if any of these c onditions exist. See Drive Be lt T roublesh[...]

11 : 0 0 2:00 + 11 8 MAINTENANCE Clutch S ystem Dr ive Belt Removal CAUTION Do not at t empt t o rem ove t he drive belt af ter operat ing in rever se. The s nowmobile mus t be s topped af t er f orward m otion t o prev ent damage t o component s dur ing belt r emoval. 1. Stop the engine a fter ope rating in a forwa rd motion. NOT E: F or eas ier a[...]

11 9 MAINTENANCE Clutch S ystem Drive B elt In stallation 1. Drop the drive belt over the drive clutch a nd pull back the sl ack. NOT E: T o ensur e sat isf act ory belt life, inst all belt s so t hey operat e in the s ame direct ion of rot ation by posit ioning the identif icat ion number s so that you c an read t hem. I f required, separ ate t he[...]

+ 120 MAINTENANCE T rack R eplacement When rep laci ng t he track , al ways i ns tal l a track h avi ng t he lu g si ze re commende d for your model. See your Polar i s dea l er . CAUTION Ins talling t rac ks wit h larger lugs on machines equipped with coolers will result in damage t o t he cooler or tunnel. A lways inst all a tr ack hav ing the lu[...]

121 MAINTENANCE T rack Lubr ication W ARNING Oper ating wit h insuff icient lubricat ion bet ween the r ail slide and tr ack guide c lips can c ause t rack failur e, los s of v ehicle c ontrol and loss of brak ing ability , which c an result in ser ious injury or death. Avoid operating f or ex tended per iods on ice and ot her s urf aces that have [...]

122 MAINTENANCE T rack T ension W ARNING Moving par ts can c ut and cr ush body par ts . W hen perf orm ing the check s and adjust ment s r ecomm ended on the f ollowing pages, st ay clear of all mov ing parts . Never perf orm t rac k measur ement or adjust ment s wit h t he engine running. T rac k adjustme nt is critic al for pr oper handling. Alw[...]

123 MAINTENANCE T rack T ension 4. C heck fo r sp ecifi ed sl ack (C ) bet ween t he wear s urface of t he t rack clip an d the plastic r ail slide. I f t he tr ac k nee ds adj ust me nt: 5. Loosen the re ar idler shaf t bolt (D). 6. Loosen the locknuts (A). 7. T ig ht en or lo os en th e track adj ust i ng screws (B ) as necess ary to provide e qu[...]

+ + 7/16 ″ (1.1 cm) 124 MAINTENANCE n T rack A lignment P erio dical l y check t hat t he track is ce ntere d and running e venly on the slide rails. Misalignme nt wil l cau se exces si ve wear t o t he tra ck a nd slide ra il. 1. Safely support the re ar of the snowmobile with the tra ck of f the ground. 2. St ar t the engine and apply a small a[...]

125 MAINTENANCE Steer ing System Steer in g Inspection an d Adjustment Each week, o r before a lon g rid e, check al l st eeri ng sy st em fast eners and t ig ht en if neces sary .[...]

X Y 10 ″ 10 ″ 126 MAINTENANCE Steer ing System S ki Ali gnment W ARNING Im proper ski alignment or adjust ment m ay cause loss of steer ing cont rol, result ing in ser ious injury or deat h. Do not at t empt t o change t he ski alignm ent or camber adjust ment . See your Polaris dealer . W ith the handle bar s in a stra ight ahea d position, an[...]

+ 127 MAINTENANCE Steer ing System n Ski S kags W ARNING Worn skis and/ or sk ags will adversely aff ect handling. Loss of vehicle cont rol may r esult , caus ing serious injury or deat h. See your dealer ’s st udding chart f or rec ommended s kags. I f y ou inst all longer or m ore aggres sive c arbide sk ags t han the or iginal equipment , it m[...]

128 MAINTENANCE Batter y W ARNING Im properly connect ing or dis connect ing bat ter y cables can res ult in an explosion and c ause ser ious injury or deat h. When remov ing the bat t ery , always dis connect t he negativ e (black ) cable f irst . W hen reinst alling t he batt ery , always connect t he negativ e (black ) cable las t. Bat tery Remo[...]

129 MAINTENANCE Batter y Batter y Stor age Whe never the ve hicle is not used for a per iod of three months or more, remo ve t he bat t ery from th e vehi cl e, en su re th at i t’ s ful ly ch ar g ed, and st ore it ou t of t he sun i n a cool , d ry pl ace. Ch eck bat tery v ol tage each mo nt h du rin g st orage and r echarge as n eeded t o mai[...]

130 MAINTENANCE Batter y Bat tery Cha rgin g For a re fre sh cha rge , follow all instruc tions car efully . 1. Chec k the batte ry voltage with a voltme ter or multimete r . A fully cha r ged batte ry will registe r 12.8 V or higher . 2. If the voltage is less than 12.8 volts, rech ar ge the batte ry at 1.2 amps or less until the batter y voltage [...]

131 MAINTENANCE Ex tended Stor age Of f-se ason or extended stora ge of your snowmobile require s preve ntive mea sures to a i d a gainst de teriora tion and to prolong the useful life of many compone nts. See page 133 for the pa rt numbers of Polaris produc ts. Cleaning and Preser vation Proper stora ge starts with c l ea ning, washing, and waxing[...]

132 MAINTENANCE Ex tended Stor age E ngine Pr otection Fogging the engine is not reco mmended for this model. CAUTION Fogging t he engine impr operly c an result in damage t o t he sensor s. F ogging is not r ecomm ended. Electr ical Connection s Rep lace wo rn or fray ed elect rical wi re and co nnect ors. Be s ure wi rin g har ness is properly se[...]

133 POLARIS PRODUCTS Part N o . Descrip ti o n Engine Lubr icant s 2874865 Perf orm ance Synthet ic 4-St roke ( PS-4) 0W 50 Oi l (qt .) 2874866 Perf orm ance Synthet ic 4-St roke ( PS-4) 0W 50 Oi l (gal .) Chaincase Lubr icant s 2873105 Synthet ic Chaincase Lubri cant (qt .) 2872951 Synthet ic Chai ncase Lubri cant ( 12 oz.) Gr ease / Special ized [...]

134 TROUB LES HOOTING Engi ne and Dr ive T r ain T r oubleshooting E ngine Spee d, RP M or B oost is Lim ited Po ssibl e Cause Sol uti on Engine M ana gem ent Sys te m RPM Red u ctio n M o de is activ ated S ee causes o n p ag e 34 . Jamm ed clu tch Che ck f or t wis te d be lt or br oken s pri ng. Se e your dea le r . Ja mmed t rac k Re move a ny [...]

135 TROUB LES HOOTING Engi ne and Dr ive T r ain T r oubleshooting Engine T urns Over , Fails to Start Po ssibl e Cause Sol uti on Out of fuel Ref uel . W ater is p resen t in fu el Se e your dea le r . Ol d or non- re com mende d f uel Re pla ce wit h fr es h r ec omme nded f uel . Foul e d or de fe ct ive s par k plugs In spect p lu g s and rep l[...]

136 TROUB LES HOOTING Engi ne and Dr ive T r ain T r oubleshooting E ngine Runs Ir r egular ly , S tops or Loses P ower Po ssibl e Cause Sol uti on Engine M ana gem ent Sys te m RPM Red u ctio n M o de is activ ated S ee causes o n p ag e 34 . Lo w b attery v o ltag e Rech arge the battery to 1 2 .8 VD C. W ater is p resen t in fu el Se e your dea [...]

137 TROUB LES HOOTING Engi ne and Dr ive T r ain T r oubleshooting Ha rsh D riv e Clutc h Engagem ent Po ssibl e Cause Sol uti on Wo r n d r i v e b e l t Rep lace w ith th e reco mm end ed b elt. E xcessiv e b elt/sh eav e clearance Se e your dea le r . Dr ive Belt T urns Over Po ssibl e Cause Sol uti on In correct b elt Rep lace w ith th e reco m[...]

138 TROUB LES HOOTING Suspension T r oubleshooting (Switchback) Pr oblem Solut ion ( perf orm only one change at a ti me) Rear su sp en sio n b otto m s too easily S V e ri fy s a g dime nsi on (s e e pa ge 50) . Adjus t t ors ion s pr ing bl ocks or i nst al l opti onal t ors ion spr ings t o ac hie ve c orr ec t sag d imen sio n s. S I ncr ea se [...]

139 TROUB LES HOOTING Suspensi on T r oubleshooti ng (M-10) Pr oblem Solution (pe rfor m only one cha nge at a tim e) Rear su sp en sio n b otto m s too easily S In crease FR A p o sition (see p ag e 56 ). S I nst al l appr opri a t e opti onal c ent er r e ta ine r on re ar t ra c k s hock ( se e page 57) . S I ncr ea se f ront tr ac k s hoc k coi[...]

140 TROUB LES HOOTING Dr ive B elt T r oubleshooting Be lt W ear /Bur n Diagnos is Causes Solutions Driv in g at lo w R PM S Driv e at h ig h er RP M . Gear th e m ach ine d o w n. C heck be lt de fl ec ti on. In sufficient w arm-u p S W ar m the e ngine a t le as t fi ve mi nute s. T ake t he dri ve bel t of f the ma chi ne i n ext r e mel y c ol [...]

141 WARRANTY Se rvi ce And W ar r anty Infor m ation Obtainin g Ser vice and W ar ranty Assistance Rea d and understa nd the ser vice data a nd the Polaris war ranty infor m a tion conta ined in this manual. Contact your Pola ris deale r for repl acemen t p arts , s ervi ce or warrant y . Y our d ealer recei ves freq uent update s on change s, modi[...]

142 WARRANTY L imi te d W a rran t y Pol a ri s Sal es I nc. , 2100 Hi ghway 55, Me dina , MN 55340, provi des a ONE YEAR LIM - I TED W ARRA NTY on al l com ponent s of the Pol ar is s nowmobil e a gai nst de fe ct s in ma te ri a l or workm ans hip. This w a rr ant y cove rs t he par ts a nd la bor cha r ge s for r epa i r or rep lacemen t o f d e[...]

143 WARRANTY Limita tions of warra nties a nd remedi es ALL IMPLI ED W ARRANTIES ( INCLUDING BUT NOT LI MITED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TI CU- LAR PURPOSE) ARE LI MITED IN DURA TION T O THE ABOVE ONE YEAR W ARRANTY PERI OD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA N TIE S N OT S T A TE D IN T [...]

144 WARRANTY Conditions and E xc lus ions I n orde r t o qual if y for wa rr ant y , the produc t m ust have be en pr oper ly s e t up a nd te st ed by a P olaris D ealer (if ap p licab le). Failu re o f an y d ealer to p erfo rm th e req u ired v eh icle P re- De li ver y Ins pec ti on, per f orm al l appl ic a bl e se rvi ce bul le ti ns a nd ha [...]

145 WARRANTY P olar is S econd Y ear Engine S er vice C ontract Se cond Y e a r Engi ne Se rvi ce Cont ra ct is s t anda rd on a ll el igi ble ne w and unus e d s nowmobil es t hat wer e Snow Chec ke d t h r ough an a uthor iz e d Pola ri s de a le r dur ing t he Ma rc h/A pri l Snow Chec k promot ion. The fr e e Sec ond Y ea r Engine Se rvi c e Co[...]

146 WARRANTY Exported V ehicles EXCEPT WHERE SPECI FICALL Y REQUIRED BY LA W , THERE I S NO W AR- RANTY OR SER VI CE BULLETIN COVERAGE ON THI S VEHICLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE S ELLI NG DEALER’S AUTHORIZED LOCA- TION. T his po licy d o es n o t ap p ly to v ehicles that hav e received au th o rization fo r e xpor t fr om Pol a [...]

147 WARRANTY S nowmobi le Engi ne E mis sions Li mite d W arr anty Th is sno w mo b ile en gin e emissio ns limited w arrant y is in ad ditio n to th e Po laris stan dard l imi te d wa rr ant y for snow mobil es . Pol a ri s Indus tr ie s Inc . wa rr ant s tha t the ne w engi ne, i ncl uding al l par ts of i ts e mi ss ion- c ontr ol sys te m, i s [...]

148 WARRANTY S nowmobi le Engi ne E mis sions Li mite d W arr anty Some st at e s do not a ll ow li mit a ti ons on how long a n impl ie d wa rr ant y la st s, so the a bove limitatio n m ay no t app ly if it is in co n sistent with th e co n trollin g state law . Th is limited w ar- r ant y exc lude s fa il ure s not c a use d by a de f e ct in ma[...]

149 MAINTENANCE LOG Pres ent t his s ectio n of your m anual to your deal er each time your snowmobile is servic ed. This will provide you and future owne rs with an accurat e log o f mai nten ance and s ervi ces perform ed on t he snowmobile. DA T E MI LE S (K M) TECHNICI AN SERVICE PERFOR MED / COMMENTS 150 mi . ( 240 km) 500 mi . ( 800 km) 1000 [...]

150 MAINTENANCE LOG DA T E MI LE S (K M) TECHNICI AN SERVICE PERFOR MED / COMMENTS[...]

151 MAINTENANCE LOG DA T E MI LE S (K M) TECHNICI AN SERVICE PERFOR MED / COMMENTS[...]

152 INDEX A Accesso ries 6 1 .................... Ad ju stab le Head lig h ts 3 0 ............ Air F ilter 1 04 ..................... Altern ato r B elt Insp ectio n 1 04 ........ A v alan ch es 1 6 .................... B Ba tt er y 128-130 ................... Ba tt er y Char gi ng 129- 130 ............ Battery In stallatio n 1 28 ............. Bat[...]

153 INDEX F Fue l Line s 103 .................... Fue l Pump 103 ................... Fue l Saf et y 73 .................... F uel S y stem D eicers 7 9 ............. Fus es 1 15 ........................ G Ga uge Cle ani ng 45 ................ Ge ar ca s e Oil 100- 101 ............... Gr ab Handl e Adj ust ment 61 ......... H Ha loge n Bulbs 1 14 ..[...]

154 INDEX S Ska gs 63 ........................ Ski Al ignme nt 126 ................. Ski Pr es sur e, M 10 58- 59 ............. Ski Ska gs 127 .................... Slid e, R ail 1 24 .................... Snow Condi t i ons 20 ............... Spa rk Pl ugs 102 ................... Spr ing Pr el oad 50 ................. St a rt ing the Engi ne 75 ....[...]