Polaris 550 IQ 136 manual

Snowmobile Owner's Manual for Maintenance and Safety 550 IQ Shift 550 IQ 136 550 IQ L XT[...]

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death . W ARNING The engine exhaust from this p roduct contains chemicals known to the S tate of California to cause cancer , birth defects or othe[...]

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

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. 9923893 Rev 01 Printed in USA *9923893 *[...]

1 WELCOME Thank you for purch asing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational[...]

2 The following are registered trademarks of POLARIS Industries Inc.: Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result betwee[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 T[...]

4 INTRODUCTION V ehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if bo th keys are lost, the ignit ion switch must be replaced.[...]

5 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam- paign. W e encourage governments to adopt rigorous safety training pro- grams that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other or ganizatio ns are working together to pro- tect [...]

6 SAFETY Operator Safety The following signal words and symbols appear throughout this 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 hazard. DANGER A DANGER indicates a hazardo[...]

7 SAFETY Operator Safety Follow the recommended maintenance pr ogram beginning on page 62 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while d[...]

8 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revolving track that must be partially exposed for proper operation. W ARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile[...]

9 SAFETY Operator Safety Riding App arel Be prepared, be warm and be com- fortable when riding. Be aware of the weather forecast, especially the wind- chill, and dress accordingly . See the chart on page 20. W ARNING! Avoid wearing loose cloth ing or long scarves, which can become entangled in moving parts and cause serious injury . Helmet W earing[...]

10 SAFETY Operator Safety Survival Prep aration For your safety , always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone. If it isn't possible to ride with others, and you must travel into remote areas, always carry survival equipment that's appropriate to the condi- ti[...]

11 SAFETY Operator Safety Rider Cap acity Driving 1-Up - Some POLARIS snowmobiles are designed for a single rider only . A decal on the console of thes e models indicates single rider operation. Never carry a passenger on a single-rider snowmobile. Driving 2-Up - Some POLARIS snowmobiles are designed for up to two riders. A decal on the console of [...]

12 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 di[...]

13 SAFETY Operator Safety A valanches Snowmobilers should always be properly 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 snow[...]

14 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may in terfere with the steering of your machine, resulting in serious inju ry or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steer[...]

15 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allow ing the engine's compression to help slow the machine and keep it from rolling freely downhill. W ARNING! When driving on long downhill st[...]

16 SAFETY Operator Safety Driving in Hilly T errain W ARNING! Climbing a hill or crossing the fa ce of a slope may result in loss of balance and machine rol l-over , causing se rious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, ke[...]

17 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt r emoved. Any servicing that requires operation wi thout a belt must be performed by your dealer . Operation of the engine with the belt removed may result in injury or damage to the engine. Int ake Silencer Do not operate the engine with the intake silencer or filte[...]

18 SAFETY Operator Safety Inadequate Snow Conditions W ARNING! Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversibl e track damage and lead to serious injury . Since snow provides the only lubr ication for the power slide suspension and, on liquid cooled mode ls, cooling for the engine, adequate snow cove[...]

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if operato rs drive improperly . If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned driv- ers should spend[...]

20 SAFETY Operator Safety Windchill/T emperature Charts The following information is provided to help you determine when tem- peratures become dangerous 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 emperature ([...]

21 SAFETY Safety Decals and Locations W arning decals have been placed on t he snowmobile for your protec- tion. Read and follow the instructions of the decals and other warnings on the snowmobile carefully . If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals[...]

22 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: St ay clear of track. Do not sit on seat back. Ent a nglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” W arning Snowmobiles designed for single- rider use have a warning decal on the low[...]

23 SAFETY Safety Decals and Locations Reverse W a rning The reverse warning decal is located on the upper console: W ARNING Reverse operation, even at low speeds, can cause loss of control resulting in seri ous injury or death. T o avoid loss of control, always: • Look behind befo re and while backing up. • A v oid sharp turns. • Shift to or [...]

24 SAFETY Safety Decals and Locations Operation W arning • T o avoi d serious injury or death, read and understand all warnings and the Owner's Manu al before operation. If manual is missing, con- t a ct a POLARIS dealer for a replacement. • This vehicle is capable of high sp eeds. Buried object s or uneven terrain can cause loss o f contr[...]

25 FEA TURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. T aillights 7. Rear Bumper 8. Snow Flap 9. Console S t orage Compartment (if equipped ) 10. Suspension 11 . Tr a c k 12. Skis 13. Nosepan 14. Front Bumper (do not use for pulling or dragging the snowmobile) 15. Passenger Grab Handle (LXT) 16. Passenger Seat (LXT) 17. Passenger [...]

26 FEA TURES 1. Fuel Filler Cap/Dipstick 2. Recoil St arter Handle 3. Reverse Indicator 4. Headlight Adjuster 5. S peedo meter 6. Engine Stop Switch 7. Choke Lever 8. Ignit ion Switch 9. Brake Lever 10. Parking Brake 1 1. Handlebar Grip W armer Switch 12. Thumbwarmer Switch 13. Electronic Reve rse Button 14. Headlight Dimmer Switch 15. Thr ottle Co[...]

27 FEA TURES Cargo Bag The accessory cargo bag is secured to the rear of the tunnel with straps. The maximum weight capacity for the cargo area is 30 lbs. (14 kg). Always secure cargo before operating. Do not exceed the weight limit. Do not allow a passenger to sit on the cargo area. Adjust able Headlight s Adjust the headlight beam by moving the a[...]

28 THE PERFECT FIT Front Suspension Adjustment s Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail conditions. W e recommend starting with factory settings and th[...]

29 THE PERFECT FIT Front Suspension Adjustment s Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o change front shock spring preload,[...]

30 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail conditions, 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 designs and adjustments involve a compromise, or trad[...]

31 THE PERFECT FIT Rear Suspension Adjustment s Suspension Performance Tip s • Rider weight usually determines the position at which the spring pre- load should be set. However , this may vary with riding style. W ith a little experimentation, each rider can find a preferred setup. These adjustments are easy to make, involve very little time or e[...]

32 THE PERFECT FIT Rear Suspension Adjustment s Initial Spring Preload Setting (Sag Method) T o set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full exten- sion. Tip : The rear bumper may need[...]

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

34 THE PERFECT FIT IQ Rear Suspension Adjustment s Suspension Coupling On all POLARIS snowmobile rear su spensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque ar ms could move independently of each other . Rear suspension coupling links the movement of the front and[...]

35 THE PERFECT FIT IQ Rear Suspension Adjustment s Suspension Coupling Rear T o Front Coupling and the Rear Rear Scissor S top (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the am ount of indepen- dent movement between the rea r to rque and the front torque arm. Adjusting t[...]

36 THE PERFECT FIT IQ Rear Suspension Adjustment s Weight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner - i[...]

37 THE PERFECT FIT T raction Product s Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steerin g and control. See page 93. If your snow[...]

38 THE PERFECT FIT Handlebar Adjustment s When making handlebar ad justments, alw ays be sure the handlebars, brake lever and throttle lever operate smoothly and do not contact the fuel tank, windshield or any other part of the vehicle when the handle- bars are turned fully to the left or right. Handlebar Position Follow these steps to adjust handl[...]

39 THE PERFECT FIT Handlebar Adjustment s Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover . 2. Loosen the four upper adjuster block bolts. 3. Adjust the handlebar to the desired angle. 4. T orque the bolts to 15-17 ft. lbs. (20-23 Nm). 5. Reinstall the handlebar cover . Accessories [...]

40 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer - enced pages. Item See Page Drive Belt Condition 83, 85 S teering System 44 Recoil Rope 45 Cooling System Seal 73 Parking Brake Lock/Bra ke Lever/Brake System 42, 43[...]

41 PRE-RIDE INSPECTIONS Before St arting the Engine W ARNING! Worn, damaged, or malfunctioning compo nent s may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Underst and Y our Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is yo[...]

42 PRE-RIDE INSPECTIONS Before St arting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2” (1.3 cm). A smaller distance indicates low brake fluid level or a ir in the hydraulic system. Refer to the bra[...]

43 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock onl y when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reser- voir/ Cover 4. Fluid Level Indicator Loc[...]

44 PRE-RIDE INSPECTIONS Before St arting the Engine Steering System Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. T rack W ARNING! Operating the snowmo[...]

45 PRE-RIDE INSPECTIONS Before St arting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission contro l and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps ar e in good condition and t[...]

46 PRE-RIDE INSPECTIONS S t art the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without check- ing all components to be sure of proper operati on. See Before S tarting the Engine beginn ing on page 41. Engine Stop Switch Check the auxiliary shut-off[...]

47 OPERA TION S tarting the Engine NOTICE: Engaging the starter when the eng ine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the fuel valve on. See page 52. 2. T urn the key to the ON position. 3. Pull the engine stop switch up to the R[...]

48 OPERA TION Emergency S t oppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 56 for more information about the engine stop switch and throttle safety switch. Break-In Period Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in[...]

49 OPERA TION Break-In Period Oil Injection System Always check and fill the oil tank when refueling. See page 53. NOTICE: Serious engine damage can occur without the proper lu brication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately . Oil Recommendations Engine [...]

50 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 machine and the moving track. Never hold the snowmobile up or stand be hind it while warming up th e track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear sup[...]

51 OPERA TION Fuel Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open fl[...]

52 OPERA TION Fuel Y our POLARIS engine is designe d to ru n on 87 octane non-oxygenated or 89 octane oxygenated pump gasolin e. There's a great deal of variabil- ity in the quality of the 87 octane gasoline available across the country , so we encourage the use of premium fuel when possible. Do not use fuel containing mor e than 10 % ethanol [...]

53 OPERA TION Oil Low Oil Indicator Light The low oil indicator light may flicke r at times due to oil movement in the bottle, but when the light comes on and remains on, add the recom- mended oil before further operation. See page 49 for oil recommenda- tions. V isually check for oil in the bottle. The engine may be operated as long as oil is visi[...]

54 OPERA TION Carburetion NOTICE: Making non-recommended adjustments could result in vehicl e or engine damage as well as denia l of warranty claims. We recommend that all carburetor adjustments be performed by your POLARIS dealer . Proper carburetor adjustment is critical. A lean mixture (too much air , too little fuel) may result in piston burnin[...]

55 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperature af fect air density , which is the amount of oxygen available for comb ustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carburetors are calib rated for an altitude of 0- 2[...]

56 OPERA TION Engine St op Switch Push down on the engine stop switch (X) to ground out the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restart- ing. 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 ca[...]

57 OPERA TION Throttle Lever W ARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or dea th. 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 switch[...]

58 OPERA TION Electronic Reverse (PERC) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet , adjust the igni- tion setting as described on page 59. Al ways make sure the vehicle is stopped and the engine is ru nning at idle before shifting to reverse Tip : The engine wi[...]

59 OPERA TION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light o[...]

60 OPERA TION To w i n g Do not use the front bumper to pu ll or drag the snowmobile. The front bumper is not designed fo r this type of use and may detach from the vehicle if force is applied. For your safety , do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions. W ARNING! Objec[...]

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

62 MAINTENANCE POLARIS Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 1 19. The recommended maintenance schedule on your snowmobile c[...]

63 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding condi tions. Y ou may need to increase frequency based on riding conditions. When inspection reveals the need for replace ment parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, l[...]

64 MAINTENANCE Periodic Maintenance Interval T able Item See Page Frequency 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 77 II II Brake Disc -- II II Parking Brake 43 II II Brake System 42, 77 I Brake Fluid 78 I FUEL MANAGEMEN[...]

65 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequency 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 S teering F[...]

66 MAINTENANCE Lubrication Front Suspension The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium All Sea- son Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 62 and before seasonal storage. When operating in heavy , wet snow conditions, lu[...]

67 MAINTENANCE Lubrication Driveshaf t Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges 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, turn t[...]

68 MAINTENANCE Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 62. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil a fter the first 500 miles (800 km[...]

69 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) 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. Tip : The sealing surfaces on the drain plug and the oi[...]

70 MAINTENANCE Spar k P l ug s It’ s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. Change the spark plu gs every 2000-2500 miles (3200- 4000 km). NOTICE: A spark plug wit[...]

71 MAINTENANCE Spar k P l ug s Sp ark Plug Condition Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white. A white insulator tip indicates overheating[...]

72 MAINTENANCE Int ake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam filters period- ically to remove any accumulation of snow . NOTICE: Operating the snowmo bile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or car[...]

73 MAINTENANCE Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the under-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur . Replace worn [...]

74 MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with incorrect jetting can result in [...]

75 MAINTENANCE Carburetor W ater/Sediment T rap Most POLARIS snowmobiles contain patented carburetor bowl water/ sediment traps located at the bottom of each carburetor . The trap, con- sisting of a hose with a plug, should be draine d about every 1000 miles (1600 km) and inspected for contamination. W ARNING! When draining the traps, fuel spillage[...]

76 MAINTENANCE Drive Chain T ension Check drive chain te nsion weekly and before each long trip. T o obtain correct chain tension: 1. Rotate the driven clutch counter- clockwise 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 (1). 3. Fin[...]

77 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect brake lever travel before eac h use of the snowmobile. See page 42. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16” or 1.5 mm). A kit is available for replacing brake pads. See your dealer . W ARNING! Brake failure during[...]

78 MAINTENANCE Brakes Brake Fluid W ARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air . The moisture causes the boiling temperature of the brake fl uid to drop, which can lead to early brake fade and the [...]

79 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system be fore operating the snowmobile. W ARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never operate[...]

80 MAINTENANCE Light s Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the headlight assembly . 2. Lift the rubber boot to expos[...]

81 MAINTENANCE Light s T aillight/Brakelight Replacement 1. Remove the screws securing the taillight lens. Remove the lens. 2. Push the bulb inward and turn it counter -clockwise to remove it. 3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it. 4. Reinstall the taillight lens.[...]

82 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. NOTICE: If you become aware of higher than normal clutch engage ment or an unusual vibration or shift pattern, see your dealer immediately . Do not operate [...]

83 MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt T roubleshooting on page 107. For imp[...]

84 MAINTENANCE Clutch System Drive Belt Inst allation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer cir - cumference of the driv en clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after th[...]

85 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inch (3.2 cm). Drive Belt Adjustment 1. Install the L-wrench into the open threaded h[...]

86 MAINTENANCE T rack Maintenance T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the machine, which could cause serious in jury or death. Never operate with a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground. 2. Rotat[...]

87 MAINTENANCE T rack Maintenance T rack Lubrication W ARNING! Operating with insufficient lubrication between the rail sli de and track guide clips can cause track failure, loss of vehicle control and loss of braking ability , which can result in serious injury or death. Avoid operati ng for extended periods on ice and other surfaces that have lit[...]

88 MAINTENANCE T rack Maintenance W ARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. T rack T ension T rack adjustment is critical for proper handling. Always mainta[...]

89 MAINTENANCE T rack Maintenance T rack T ension 4. Check for specified slack between the wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 88. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 7. T ighten or loosen the track adjusting screws to provide [...]

90 MAINTENANCE T rack Maintenance T rack Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track of f the ground. 2. Star t the engine and apply a small amount of throttle until the trac[...]

91 MAINTENANCE S teering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary . X X X X X[...]

92 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alig nment or adjustment may cause loss o f steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dea ler . 1. Place the handlebars in a straight-ahe ad position. 2. W ith only vehicle weight compr[...]

93 MAINTENANCE S teering System Ski Skags See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle con- trol while turning on hard-packed snow or ice. W ARNING! Worn skis and/or skags will ad[...]

94 MAINTENANCE S teering System Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum per - missible slide thickness. 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 [...]

95 MAINTENANCE Daily St orage At the end of each ride, park the sn owmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) of f the ground. Remove the key and cover the machine. Fall T une-Up For maximum performance, arrange for a fall service tune-up wit[...]

96 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a co ol dry location. Do not lubricate clutch components, except the driven clutch shaft bushing a[...]

97 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and ho t exhaust parts. T rack and Suspension Moderate track tension should be maintained during summer storage. The machine should be support[...]

98 SPECIFICA TIONS 550 IQ SHIFT Capacities and Dimensions Body St yle IQ Rider Capacity 1 Coolant Capacity N/A Fuel Capacity 1 1.5 gal . (43.5 l) Oil Capacity 3 qts. (2.8 l) Gearcase Oil Capacity 8.96 oz. (265 ml) Length 1 15 in. (292 cm) W idth 47.25 in. (120 cm) Height 44.5 in. (113 cm) Brake T ype Hayes Phantom DOT 4 Drive Clutch Center Distance[...]

99 SPECIFICA TIONS The carburetor jettin g chart above is consistent with t he provisions of U.S.A. f ederal regulation 40 CFR 1051.1 15(d)(3) and is an acceptable altern ative to the use of t amper-resist ant features. 550 IQ SHIFT Carburetor Jetting *Shaded cells indicate factory sett ings. AL TITUDE Meters (Feet) AMBIENT TEMPERA TURE °F: Below [...]

100 SPECIFICA TIONS 550 IQ 136 / 550 IQ LXT Capacities and Dimensions Body St yle IQ Rider Capacity Shift 136/ES: 1 Rider IQ LXT : 2 Riders Coolant Capacity N/A Fuel Capacity 1 1.5 gal . (43.5 l) Oil Capacity 3 qts. (2.8 l) Gearcase Oil Capacity 8.96 oz. (265 ml) Length 125 in. (318 cm) W idth 47.25 in. (120 cm) Height 44.5 in. (1 13 cm) (low winds[...]

101 SPECIFICA TIONS The carburetor jettin g chart above is consistent with the provision s of U.S.A. federa l regulation 40 CFR 1051.1 15(d)(3) and is an acceptable alternati ve to the use of tamper-re sistant features. 550 IQ 136 / 550 IQ LXT Carburetor Jettin g *Shaded cells indicate factory sett ings. AL TITUDE Meters (Feet) AMBIENT TEMPERA T UR[...]

102 POLARIS PRODUCTS Part No. Description Engine L ubricant s 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) 2875038 Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l) 2877883 VES Gold Plus 2-Cyc[...]

103 TROUBLESHOOTING Engine T roubleshooting Unless you have experienc e and training in two-cycle engine r epair , s ee your dealer if technical pr oblems arise. Problem Probable Cause Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • Disassemble drive clutch to inspect shift weights for wear a[...]

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

105 TROUBLESHOOTING Engine T roubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spa rk. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. • Make sure fuel tank conta[...]

106 TROUBLESHOOTING Rear Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 32). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). • Rotate RRSS to higher position (see page [...]

107 TROUBLESHOOTING Drive Belt T roubleshooting Belt We ar/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at highe r RPMs. 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 machi ne in extremely cold weather and warm it up. Break machine loose fr[...]

108 W ARRANTY Service and W a rranty Information Obt aining Service and Warranty Assist ance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty . Y our dealer receives frequent updates on changes, modifi- cations and tips on snowm[...]

109 W ARRANTY Service and W a rranty Information POLARIS Anti-Thef t System The POLARIS anti-theft syst em (P A TS) monitoring program is desig ned to aid owners of registered sno wmobiles in recovery of stolen machines. Administration 1. POLARIS snowmobile owner reports theft. A. In addition to notifying the proper law enforceme nt of ficia ls, th[...]

110 W ARRANTY Limited W arranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED W ARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. This warranty covers th e parts and labor charges for repair or replacement of defective parts that are covered by this warranty . The wa[...]

111 W ARRANTY W arranty Coverage and Exclusions Limit ations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmansh ip. The warranty does not cover ac cidental damage, normal wear and tear , abuse or improper handling. The warranty also does not cover any snowmobile that has been structurally [...]

112 W ARRANTY W arranty Coverage and Exclusions Limit ations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLU DING 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 T O THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISC LAIMS ALL EXPRESS W AR- RANTIES N[...]

113 W ARRANTY W arranty Coverage and Exclusions Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a POLARIS Dealer (i f applicable). Failure of any dealer to perform the required vehi- cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con- sumer sig[...]

114 W ARRANTY W arranty Coverage and Exclusions Conditions and Exclusions W arranty applies to the product only and does not allow for coverage of personal loss. Some items are considered “consumabl e,” meaning they are considered part o f normal maintenance or part of completing an effective re pair . The following items are excluded from warr[...]

115 W ARRANTY Exported V ehicles EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA- TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Deale[...]

116 W ARRANTY Exported V ehicles How to Get Service If Y o u Move: If you move to another country , be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. V ehicles importa- tion rules vary considerably from country to country . Y ou may be required to present documentation of your move[...]

117 W ARRANTY U.S.A. EP A Emissions Limited W arranty This emissions limi ted warranty is in add ition to t he POLARIS standard limited war - ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-c ertified vehicle is designed, built and equipped so it conforms with applicable U.S. Environ[...]

118 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this limi ted warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THIS[...]

119 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and services 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. [...]

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

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

122 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 39 Adjustable Hea dlights . . . . . . . . . . . 27 Air Polluti on . . . . . . . . . . . . . . . . . . . 5 Altitude Setting . . . . . . . . . . . . . . . . 59 Avalanches . . . . . . . . . . . . . . . . . . . . 13 B Bearings . . . . . . . . . . . . . . . . . . . . . . 96 Before Starting th[...]

123 INDEX F Front Rear Scissor Stop . . . . . . . . . . 34 Front Suspension Adjustments . . 28-29 Front To Rear Coupling . . . . . . . . . . 34 FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fuel . . . . . . . . . . . . . . . . . . . . . . . 51-52 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73 Fuel Lines . . . . . . . . . . . .[...]

124 INDEX R Rider Capacity . . . . . . . . . . . . . . . . . 11 Riding Apparel. . . . . . . . . . . . . . . . . . 9 Riding Position . . . . . . . . . . . . . . . . . 8 RRSS . . . . . . . . . . . . . . . . . . . . . . . . 35 S Safety Decals . . . . . . . . . . . . . . . . 21-24 Safety Symbol s . . . . . . . . . . . . . . . . . 6 Sag . . . . . . . . [...]