Polaris Trail Touring manual

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Pantone 280 CVC 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. 9922285 Rev 01 Printed in USA[...]

W ARNING Read, understand, and follow all of the in structions and sa fe ty precau tions in this manual a nd on al l product lab els. F ailure to follow the safety precautions could result in serious injury or death. W ARNING The engine exhaust from this product co ntains chemicals known to the State of California to cause cancer , birth defects or[...]

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 onli ne at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more. Here at Polaris we proudly produce an exciting line of utili ty and recre- [...]

2 POLARIS and POLARIS THE W A Y OU T are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some minor discre[...]

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

4 INTRODUCTION V ehicle Identification Numbers Record your sno wmobile's identificati on numbers and k ey number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a Po laris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replac [...]

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourag e governmen ts to adop t rigorous safety training pro- grams that encourage protection of ou r environment, including wildl ife and vegetation. Snowmobile clu bs and other or ganizations are working together to pro- [...]

6 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The safety alert symbol , on yo ur vehicle or in thi s manual, indicates th e potential for serious in[...]

7 SAFETY Operator Safety Follow the recommend ed maintenance prog ram beginning on page 70 of this manual to ensure that all critical components on the sn owmobile are thoroughly i nspected by your d ealer at specific mileage intervals. Driving a snowmobi le requires your ful l attention. DO NOT drink alcohol or use drugs or medications before or w[...]

8 SAFETY Operator Safety S t ay Clear of T rack Y our snowmobile is propelled by a rev o lving 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 remai n properly seated to stay clear of the track. Never hold the snowmo[...]

9 SAFETY Operator Safety Riding App arel Be prepared, be warm an d be com- fortable when riding. Be aware of the weather forecast, espec ially the wind- chill, and dress accordingly . See the chart on page 21. W ARNING! A void wearing lo ose clothing or long scarves, which can become entangled in moving part s and cause serious injury . Helmet W ea[...]

10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmo biles, but under many co nditions, the proper position is to be seated with both feet on the ru nning boards and both hand s on the handlebar grips for pro[...]

11 SAFETY Operator Safety Disabled Operators Safe operation of th is rider -active vehi cle requires good judgement and physical skills. Operators with cognitiv e or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Cargo Overload T oo much weight on the rear of th e machine may reduce [...]

12 SAFETY Excessive S peed Always observe a ll laws governing sn owmobile operation a nd speed limits. Always be alert and pay atten tion to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the ap proximate number of feet per sec- ond your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per sec ond. If yo[...]

13 SAFETY Operator Safety Driver A wareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling 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 [...]

14 SAFETY Operator Safety A valanches Snowmobilers should always be p roperly trained and equipped before traveling in mountainous terrain: • T ake an avalan che cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each pers on is equipped with a shovel, probe and avalanche beacon. Y ou don't have to be s[...]

15 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remo ve ice and snow build -up that may be obstructing the steering linkage. W ARNING! Ice and snow build-up may in terf ere with [...]

16 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Appl y just enough throttle to keep the clutch engage d, allowing the engine 's compres sion to help slow the machine and keep it fro m rolling freely downhill. W ARNING! When driving on long downhi[...]

17 SAFETY Operator Safety Driving in Hilly T errain W ARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machin e roll-over , causing se ri ous i njury or deat h. Use caution and good judgement when driv ing in hilly terrain. Use extra caution when operating in hi lly terrain. If climbing a hill is unavoidable[...]

18 SAFETY Operator Safety Clutch Guard Do not operate the engine with the clutch guard r emoved. The clutch g uard is designed to pro tect the operator from metal parts if the clutch sh ould fail. Althou gh th e ch ance of failure is extremely remote, don't defeat the purpose of the safety guard by removing it. Clutches Do not attempt to servi[...]

19 SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are includ ed on some Polaris snowmobiles. They are normally left open and are located on the front up per and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20 _ F), Polaris recommends closing the up per hood closure. NOTICE: Driving i[...]

20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if operators drive improperly . If you're new to snowmobiling, acquaint your self with the machine and with what it will and won't do under va rious conditions. Even seasoned driv- ers should spen[...]

21 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when tem- peratures be come da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind S peed in MPH Actual Thermometer Readi ng ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperatur[...]

22 SAFETY Safety Decals and Locations W arning decals have been placed on the snowmobile for your protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If a ny of the decals depicted in this manual differ from the decals on your snow mobile, always read and follow the instructions of the deca[...]

23 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: W ARNING St ay clear of track . Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death. Passenger W arning Polaris touring models are designed for the operator and one passenger . Fo[...]

24 SAFETY Safety Decals and Locations Electronic Reverse W arning Polaris snowmobiles equipped with electronic reverse have a reverse warning decal on the lower dash: W ARNING Reverse operation, even at low speeds, can cause loss of con- trol resulting in serious injury or death. T o avo id loss of con- trol, always: • Look behi nd before and whi[...]

25 SAFETY Safety Decals and Locations Operation W arning The operation warnin g decal is located on the console: W ARNING • T o avo id serious in jury or death, read and under stand all warnings and the Ow ner's Manual be fore oper ation. If manual is missing, con- t a ct a Polaris dealer for a rep lacement. • This vehicle is capable of hi[...]

26 FEA TURES Some Polaris snowmobiles are equipp ed with special feature s. Operat- ing controls and special feature cont rols are illustrated on this page. Not all models come with all special featur es. See your Owner's Man ual Supplement. 1. Fuel Filler Cap 2. Ignition Sw itch 3. Brake Lever 4. S peedom eter 5. T a chomete r 6. Engine S top[...]

27 FEA TURES 1. Front Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Handleba r 6. Operator Seat 7. Passenger Grab Handle 8. Passenger Seat 9. Passenger Backrest 10. Suspension 11 . T r a c k 12. T railing Arm 13. Nosep an 14. Ski 15. T aillights 16. Rear Bumper 17. Snow Flap 3 2 6 4 5 8 11 1 10 12 [...]

28 FEA TURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to rais e or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest forward for operator use or rearward for passenger use. 3. Always tighten the knobs securely after adjusting. Operator/Passenge r Raise[...]

29 THE PERFECT FIT Front Suspension Adjustment s Independent Front Suspension (IFS) Break in the suspension for about 150 miles (24 0 km) before making any fine-tuning adju stments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions. W e recommend starting with factory settings and[...]

30 THE PERFECT FIT Front Suspension Adjustment s W ARNING! Improper ski alignment o r adjust ment may cause loss of steering control, resulting in serious inj ury or death. Always verify ski alignment before making adjustments to the IFS. See p age 100 to check alignment. Do not attempt to chang e the ski alignment or camber ad justment. See your P[...]

31 THE PERFECT FIT Front Suspension Adjustment s S pring Preload Increasing spring preload will increase ski-to-ground pressure. Decrea sing spring preload will decrease ski-to- ground pressu re. When adjusti ng, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o increase front shock spring preloa d,[...]

32 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail co nditions, and vehicle speed all affect 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 adjustm ents involv e a comp romise, or t[...]

33 THE PERFECT FIT Rear Suspension Adjustment s Suspension Performance T ip s • Rider weight usually determines th e position a t which the spring pre- load should be set. However , this ma y vary with riding style. W ith a little experimentation, each rider can find a preferred setup. These adjustments are easy to make, involv e very little time[...]

34 THE PERFECT FIT EDGE 136 Rear Suspension Adjustment s Initial S pring Preload Setting (Sag Method) T o set up the EDGE rear suspension torsion spring prel oad, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. Tip : The rear b[...]

35 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s Rear S pring T ension T o adjust rear torsion spring tension, rotate the three-position cam usi ng the engin e spark plug tool . Different rate torsion springs are available if a firmer ride is desired. See yo ur dealer for more information. The following information is provided only as a gu[...]

36 THE PERFECT FIT EDGE 136 Rear Suspension Adjustment s Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shoc k, which allows for adjustments to the compression valving. Locate the adjust- ment screw near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiff[...]

37 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s Optional T orsion Springs Different rate torsion springs are ava ilable for some shocks if a firmer ride is desired. Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear susp ensions, there are two torque arms that control the mo vement of the rail bea[...]

38 THE PERFECT FIT EDGE 136 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 ar m and limits the am ount o f indepen- dent moveme nt between the rear to rque and the front torq ue arm. Ad[...]

39 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s W eight 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 condi- tions. T o decre ase weight transfer under acceleration (for improved[...]

40 THE PERFECT FIT Handlebar Adjustment Follow these steps to adjust handle bar angle at the hand lebar block. 1. Remove the handleb ar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7 /16-inch wrench , loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the re[...]

41 THE PERFECT FIT T raction Product s Stu d s Before equipping your machine with traction products, be aware of the laws in your area pertaining to th e use of traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. [...]

42 THE PERFECT FIT T raction Product s n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to a ssist in turning the snowmob ile and to prevent ski wear caused by contact with roads and other bare terrain. Us e carbide skags with studded tracks to help maintai n proper vehicle steering and con trol. See page 101. If you[...]

43 THE PERFECT FIT T raction Product s W ear Strip s T o avoid excessive tunnel wear , tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. W ear strips are designed for a specific stud length. See your dealer's studding chart for recommended traction accessories. Components as viewed from[...]

44 THE PERFECT FIT Accessories Polaris of fers a wide range of accesso ries for your snowmobile to h elp make each ride more enjoyable. Use only Polaris parts and accessorie s on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injur[...]

45 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the re fer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspect ion items. Item See Page Drive Be lt Condition 89, 92 S teering Sys[...]

46 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. W ARNING! Operating the vehicle with worn , damaged, or malfunctioni ng components coule result in ser[...]

47 PRE-RIDE INSPECTIONS Before St arting the Engine n Hydraulic Brakes Always check the following items fo r proper operation before starting the engin e. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip th an 1/2 I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Ref[...]

48 PRE-RIDE INSPECTIONS Before St arting the Engine n Parking Brake Lever Lock Y our snowmobile may have a parking brake lever lock located over the brake lever . Use the brake lever lock on ly when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Bra[...]

49 PRE-RIDE INSPECTIONS Before St arting the Engine n S teering System W ARNING! Ice and snow build-up may in terf ere with the steering of your machine, resulting in serio us injury or death. Keep the underho od area free of snow and ice. Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with[...]

50 PRE-RIDE INSPECTIONS Before St arting the Engine n Hood Latches The hood of the sn owmobile protects the op erator from moving parts as well as aiding in sound e mission control and other functio ns. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that th e hood straps are in good condition [...]

51 PRE-RIDE INSPECTIONS S t art the Engine and Check n Engine S top Switch Check the auxiliary shut-of f switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when th e ignition switch is turned to OFF . n Lighting Check the headlight (high and low beam), [...]

52 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engi ne is running WILL result in serious engine damage, especi ally if the tr ansmission is in r everse. Never engage the starter when the engi ne is running. 1. T urn the fuel valve on. See page 57. 2. T u rn the key to the ON position . 3. Pull the engine stop switch up to[...]

53 OPERA TION Engine Break-In No single action on yo ur part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to th e lubrication supplie d by the injection system, will assure prop[...]

54 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 59. NOTICE: Serious engine damage can occur without the prope r lubrication. Check the oil tank level often during t he first tank of fuel. If the oil level doesn't go down, contact your dealer immediately . Oil Recommendations Engine[...]

55 OPERA TION T rack W arm-Up W ARNING! Use of traction products such as studs, ice g rowsers, etc. will increase the possibi lity of track damage and /or failure. This could cause lo ss of control, resulting in serious inj ury or death. Always inspect for track damage before operating the snowmobile. Follow these steps to ensure proper warm-up of [...]

56 OPERA TION Slide Rail and T rack Cooling NOTICE: Inadequate cooling an d lubrication will lead to overheating of the slide rail and track, resulti ng in prematur e wear and failure . Reduce speeds and frequently drive into fresh s now to allow adequate cooli ng and polishing of the slide ra il and tra ck surfaces. Avoid operating on ice, hard-pa[...]

57 OPERA TION Fuel Fuel V alve T urn the fuel valve clockwis e to OFF to shut of f the fuel supply . T urn the valve counter-clockwise to ON to turn the fuel supply on. Fuel Recommendations Y our Po laris engine is designed to run on 87 octane n on-oxygenated or 89 octane oxygenated pu mp gasoline. There's a great deal of variability in the qu[...]

58 OPERA TION Fuel Fuel Reserve Cap acity (Mechanical Gaug e) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxy genated fuel, Polari s re commends th e regular u se of isopropyl-based fu el system deicer . Add on e to two ounces per gallo n (8-16 ml per lite[...]

59 OPERA TION n Oil Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. If oil is not visible, continued opera- tion may cause serious engine damag e. Add oil before further operation of the snowmobile. Low Oil Level Maintaining the proper oil level w ill prev[...]

60 OPERA TION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments. A lean mixture (too much air , too li ttle fuel) may result in piston burn- ing, bearing failure, or complete engine failure. A ri ch mixture (t oo much fuel, too little air) may foul plugs and cause generally poor[...]

61 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e affect air density , which is the amount of oxygen available for com bustion. In low elevations and cold temperatures, the air has more oxygen . In higher e levation s and high er temperatures, the air is less dense. The carbu retors are calibrated for a n a ltitude o[...]

62 OPERA TION n Engine S top Switch Push down on the engine stop switch ( + ) to ground ou t the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all pressure is removed from the throttle lever and the thrott[...]

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

64 OPERA TION Emergenc y S topping The following chart lists methods for stopping the snowmobile in the event of an emer gency . See page 62 for more information about the engine stop switch and throttle safety switch. W ARNING! Excessive or repetitive use of brakes for high speed stops will cause an over heated brake system. Th is overheated condi[...]

65 OPERA TION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RP M is below 4000. If your machine is running at an altitude of over 6000 feet, adju st the igni- tion setting as described on page 67. Al ways make sure the vehicle is stopped and the engine is running at idle before shifting to reverse. W ARNING! Impro[...]

66 OPERA TION Electronic Reverse (PERC t ) 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 reve rse but- ton ( + ) on the left-hand con- trol for one second, the n release. The engine will auto- matically reduce RPM and start a reverse rotation. A flashing [...]

67 OPERA TION Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: Engaging the starter when th e engine is running WILL resul t in serious engine damage, especi ally if the tr ansmission is in r everse. Never engage the starter when the engi ne is running. 2. Push the yellow reve rse button f[...]

68 OPERA TION To w i n g Do not use the f ront bump er to pull or drag the snowmobi le. The front bumper is not de signed for this type of use and may detach from th e vehicle if force is applied. For your safety , do not attempt to use a tow hitch until you've read the following warnings and u nderstand the proper hitch functions. W ARNING! O[...]

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

70 MAINTENANCE 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 L og beginning on page 128. The recommended maintenanc e schedul e on your snowmobi l[...]

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

72 MAINTENANCE Periodic Maintenance Interval T a ble Item See Page Frequenc y 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 84 II II Brake Disc -- II II Parking Brakes 48 II II Brake System 47, 84 I Brake Fluid 85 R FUEL MANAGE[...]

73 MAINTENANCE Periodic Maintenance Interval T a ble I - Inspect (clean, adjust, tighten, lub ricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequenc y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I S teerin[...]

74 MAINTENANCE Lubrication Suspension and Steering Lubricate the suspension and steer ing components with Polaris Pre- mium All-Season Grease at 500 mile s (800 km) and annually or every 1000 miles (1600 km) thereafter . See page 1 1 1 for the pa rt numbers of Polaris products. The illustration shows the lubrication points of suspension and steerin[...]

75 MAINTENANCE Lubrication EDGE 136 Rear Suspension Driveshaf t Bearing Inject grease into th e fitting on the speed- ometer sensor housing until grease pur ges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil.[...]

76 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at th e intervals outlined in the mainte- nance charts beginning on pa ge 70 . Change the chaincase oil after the first 500 miles (800 km), t hen every 1000 miles (1 600 km) or season- ally . Maintain the oil level between the “safe ” marks on the dipstick. Clean the magne[...]

77 MAINTENANCE Spar k P l u g s It’ s very important to use the corre ct spark p lug for your machine. A spark plug with a heat range too hi gh will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. NOTICE: A sp ark plug with a heat range too hig h will always cause e ngine dam- ag[...]

78 MAINTENANCE Spar k P l u g s Normal Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be wh ite. A white insulator tip indicates overheating, caused by use o[...]

79 MAINTENANCE Int ake Filters The intake foam filter ( + ) l imits snow ingestion into the intake system. When operating in loose powder snow , check the top of the foam filter periodically to re move any accum ulation of snow . NOTICE: Operating the sno wmobile with the i ntake filters removed may cause carburetor icing. The result will be poor f[...]

80 MAINTENANCE Fuel Filter/Fuel Lines The fuel filter is located inside th e fuel tank. This component requires no maintenance. Inspect the fuel lines re gularly for signs of deterior ation or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur . Replace worn or damaged[...]

81 MAINTENANCE Carburetor The numb er 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 responsi bility to make sure the correct main jet is installed. NOTICE: Operating the snowmobil e with incorrect jetting can result [...]

82 MAINTENANCE Carburetor W ater/Sediment T rap Service Most Polaris snowmobiles contain pa tented carbure tor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, consisting of a hose with a plu g, should be drained at least every 2000 miles (3 200 km) and inspected for contamination. W ARNING! When draining the traps, [...]

83 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at ap proximately 2000 miles (3200 km). T o inspect, allow the engine and exhaust system to cool completely . Open the hood an d inspect the muffler and pipes for cracks or damage. Ch eck for weak or missing retaini ng springs or damper/support grommets. CAUTION! Hot exhaust [...]

84 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 47. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approxima tely 1/16 inch/1.5 mm). A kit is available for replacing brake pads. S ee your dealer . W ARNING! Brake failure[...]

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

86 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snow mobile. W ARNING! Operating the vehicle wi th a spongy brake lever can result in loss of brakes, which could cause an accident and lead to seriou s injury or death. Never oper[...]

87 MAINTENANCE Light s Headlight Adjustment The headlight may be adjusted for ve rtical aim using the following pro- cedure. 1. Place the snowmobile on a level surface with the he adlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floo r to the center of the headlight and make a mark on the wall. 3. Star t the eng[...]

88 MAINTENANCE Light s NOTICE: Do not touch a halogen bulb wi th 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 to wel. Headlight Bulb Replacement 1. Pinch the ends of th e spring (1) together and lift until it releases from [...]

89 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 p attern, see your dealer immedi ately . Do not operat[...]

90 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operat ing in a forward motion. NOTICE: Do not attempt to remove th e drive belt after ope rating i n reverse. The snowmobile must be stopped after forward motion to preven t damage to components during bel t removal. 2. T urn the ignition key off. W ait fo r the engine to sto[...]

91 MAINTENANCE Clutch System Drive Belt Inst allation 1. Drop the drive belt over the drive clutch and pull back the slac k. Tip : T o ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identifica tion numbers so that you can read them. If required, separate the sheaves as outline d in [...]

92 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and ap ply downward pre ssure while measuring at point 2. This measurement sh ould be 1 1/4 inches (32 mm). Drive Belt Adjustment Belt deflection can be adjusted with out r[...]

93 MAINTENANCE Clutch System T orque S top If your snowmobile is equipped with an engine torque stop, periodically check torque stop clearance. W ith clutches in proper alignment, the torque stop clearance should be .010- .030 inch (.25-.75 mm) from the engine c ase. Adjust if necessary , and lock the jam nut. Reverse Maintenance If your snowmobile[...]

94 MAINTENANCE Chain T ension Maintain the proper chain tens ion as outlined on page 83. Fall T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and tr ained service technician will keep your machine in peak operating condition. To o l K i t A tool kit is included with each machine for em[...]

95 MAINTENANCE Tr a c k T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the machine, which could cause seriou s in jury or death. N ever operate wi th a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safel y lift and support the rear of the snowmobile of f the ground. 2. Rotate the t[...]

96 MAINTENANCE Tr a c k Moving part s can cut and crush body part s. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measurement or adjustments with the engine run- ning. T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect t[...]

97 MAINTENANCE Tr a c k T rack T ension If the track needs adjustment: 6. Loosen the rear idler shaft bolts. 7. Loosen the locknuts. 8. T ighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track. 9. Repeat the measure - ment on the other side of the track. Tip : Check more frequentl y when the machine is ne[...]

98 MAINTENANCE Tr a c k n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause exce ssive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track off the ground. 2. Star t the engine and apply a small amount of throttle until the track turn[...]

99 MAINTENANCE S teering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at an y point along their length. Failure to do so may result in per- manent damage to the track o[...]

100 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjust ment may cause loss of steering control, resulting in serious inj ury or death. Do not attempt to cha nge the ski alignment or camber adjustmen t. See your Polaris dealer . W ith the handlebars in a st raight ahead position, and with vehi cle weight compressi[...]

101 MAINTENANCE S teering System n Ski Skags See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide sk ags than the original equipment, it may also be necessary to add track st uds to maintain proper vehicle con- trol while turni ng on hard-pack ed snow or ice. W ARNING! W orn skis and/or skags[...]

102 MAINTENANCE Battery Battery electrolyte is poisono us. It contai ns acid! Serious burns can resu lt from contact with the skin, eyes, or clo thing. If contact occurs, seek immediate medi- cal attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water . INTERNAL: Drink large quan tities of water or milk. Call physicia n immediately . E[...]

103 MAINTENANCE Battery Battery Removal W ARNING! Improperly connecting or disconnecti ng battery cables can result in an explosion and cause serious inju ry or death. When removing the battery , always disconnect the neg ative (black) cable first. When re installing the battery , always connect the negative (black) cable last. 1. Disconnect batter[...]

104 MAINTENANCE Battery Battery Inst allation W ARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. 1. Ensure that the battery is fully charged. 2[...]

105 MAINTENANCE Battery Batter y S torage When your snowmo bile is placed in storage for one month or more: • Remove the battery . • Char ge it to the proper level. • S tore it in a cool dry place. • Check and/ or charge monthly . • Have the battery tested and rechar ged before reinstalling it in the vehicle. If a battery with a low charg[...]

106 MAINTENANCE n Pre-Ride Suspen sion Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems. Check the follow- ing items on a weekly basis or before any long trip: n Check suspension moun tin[...]

107 MAINTENANCE Extended S torage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many compon ents. See page 1 1 1 for the part n umbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleanin g, washing, and waxing the hood, ch[...]

108 MAINTENANCE Extended S torage Bearings Grease the drive shaft c lutch side bearing with Polaris Premium All- Season Grease or a similar high qu ality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. T o prevent oxida- tion on the clutch sheaves, lubricate the sheave faces of the drive [...]

109 MAINTENANCE Extended S torage Engine and Carbur etor Protection Using a fuel stabilizer and topping of f the fuel tank eliminates the need to drain the fuel system. If you prefer to drai n the fuel tank, use the fol- lowing procedure 1. T ransfer un used fuel from the fuel ta nk to an appro ved fuel con - tainer using a siphon pump. Do not re-u[...]

110 MAINTENANCE Extended S torage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack conn ector blocks with diel ectric grease and re-connec t. Replace worn or frayed electrical wi re and conn ectors. Be sure wiring harness is properly sec ured away from sharp edges, steering [...]

111 POLARIS PRODUCTS Part No. Description Engine Lubric ant s 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 P[...]

112 TROUBLESHOOTING Engine T r oubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- ating RPM during accelerati on or load variations Drive clutch binding • Disasse mble drive clutch to i nspect shift weights for wear a[...]

113 TROUBLESHOOTING Engine T r oubleshooting 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 replac[...]

114 TROUBLESHOOTING Engine T r oubleshooting 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 spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. See page 52. • Make sure f[...]

115 TROUBLESHOOTING EDGE 136 Suspension Problem Solution Rear suspension bottoms too easily • Increase torsion spring preload • Increase rear shock compre ssion damping by turning screw clockwise • Increase torsion spring wire diameter (see your dealer) • Rotate RRSS to a higher position. See page 39. Rides too stiff in rear • Check for b[...]

116 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at l ow RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt of f the machine in extrem ely cold weather and warm it up. Break machine loose f[...]

117 W ARRANTY Service and W a rranty Information Obt aining Service and W arranty Assist ance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warra nty . Y our deale r receives frequent updates on changes, modifications and tips on [...]

118 W ARRANTY Service and W a rranty Information Polaris Anti-Thef t System The Polaris anti-theft system (P A T S) monitoring prog ram is design ed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the [...]

119 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Polaris snowmobile against defects in material or workma nshi p. This warranty covers the parts and labor char ges for repair or replacemen t of defectiv e parts that are cove red by this warranty [...]

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

121 W ARRANTY Conditions and Ex clusions In order to qualify for warranty , the product must have been prop erly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perfor m all applicable service bulle tins and have the consumer sign the PDI form prior to delivery ma[...]

122 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y ear Engine Service C ontr act is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer d uring the March/April Snow Check promot ion. The free Second Y ear E ngine Service Contract is honored by all authorized Pola ris sn[...]

123 W ARRANTY Polaris Second Y ear Engine Service Contract Coverage Coverage for second year en gine failures d ue to defects in materials and workmanship will be determined by Polaris in its sol e di scretion. Coverage is automatic with no addi- tional paperwork required. The free Second Y ear Engine Servic e Contract is subject to a $50 deductibl[...]

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

125 W ARRANTY Exported V ehicles How to Get Service In the Country whe re your vehicle was purchased: W a rranty or Service Bulletin repairs must be done by an authorized Polaris dealer . If you move or are traveling within the country wh ere your vehicle was purchased, W arranty or Service Bulletin repairs may be requested from any authorized Pola[...]

126 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited war ranty is in add ition to the Polaris standard lim ited warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified veh icle is designed, built and equipped so it conforms with applica- ble U.S. Environm[...]

127 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REMEDIES SET FOR TH IN THIS L IMITED W ARRANTY ARE T HE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

128 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 with an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. [...]

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

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

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

132 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 44 Air Box Warnin g . . . . . . . . . . . . . . . 22 Air Pollut ion . . . . . . . . . . . . . . . . . . . 5 Altitude S etting . . . . . . . . . . . . . . . . 67 Avalanches . . . . . . . . . . . . . . . . . . . . 14 B Backres t . . . . . . . . . . . . . . . . . . . . . . 28 Battery . . . [...]

133 INDEX H Handlebar Adjust ment . . . . . . . . . . . 40 Headlight A djustment . . . . . . . . . . . . 87 Headlight Bul b Replacement . . . . . . 88 Hood Latches . . . . . . . . . . . . . . . . . . 50 I Ice and Snow Bu ild-up . . . . . . . . . . . 15 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 IFS Adju stments . . . . . . . . . .[...]

134 INDEX S Survival Preparation . . . . . . . . . . . . 10 Suspension Adjustments . . . . . . . 34-39 Suspension Adjustments, Front . . 29-31 Suspension Adjustments, Rear . . 32- 33 Suspension Coupling . . . . . . . . . . 37-38 Suspension Inspection, Pre-Ride . . 106 Suspension Lubrication . . . . . . . . 74-75 Suspensi on Performance Tips . . . .[...]