Polaris 120 Dragon manual

P antone 426C Snowmobile Owner's Manual for Maintenance and Safety[...]

P antone 426C 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. 9922313 Rev 01 Printed in USA[...]

WA R N I N G Read, understand, and follow all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or dea th. WA R N I N G The engine exhaust from this product co n tains chemicals known to the S tate of California to cau se cancer , birth de f[...]

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

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. V isit us online at www .polarisindus- tries.com for the latest news, ne w product introductions, up coming events, career opportunities and more. At Polaris we proudly produce an exciting line of utility and recreational products. ?[...]

2 WELCOME Dear Parents: W e believe your children should have the opportunity to enjoy The W ay Out experience along with you. W e've provided this owner's manual to assist you and your children in learning about the safe operation an d care of your new Polaris snowmobile. Please review the info rmation in this manual with any ch ild who [...]

3 WELCOME Dear Children: Before you ride your new Polaris sn owmobile, there are some important things that you need to k now . Y our parents and Polaris want you to enjoy riding your new snowmobile, an d that's why you n eed to re ad and understand the information in your ow ner's manual. Ask your parents to explain anythi ng you don&apo[...]

4 POLARIS and THE W A Y OUT are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may [...]

5 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Important Notes for Owners and Dr ivers . . . . . . . . . . . . 6 Preservation of the Envi ronment . . . . . . . . . . . . . . . . . . 7 V ehicle Identification Numbers . . . . . . . . . . . . . . . . . . . 9 Safety . . . . . . . . . . . . . . . . . . . . . [...]

6 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when th e snowmobile is sold. Y ou and your dealer must complete the registration form included with your snowmobile and forward it to us . This completed form is necess ary to [...]

7 INTRODUCTION Preservation of the Environment T each your child to drive the ir snow mobile with consideration for the protection and preservatio n of the environm ent. Noise One of the most publicized subjects with regard to snowmobiles is noise. The Society of Automotive E ngineers (SAE), which is the stan- dard-setting body for snowmobiles, has[...]

8 INTRODUCTION Preservation of the Environment Environmental Protection As part of the contin uing enviro nmental education campaign, we are encouraging state and provincial go vernments across the sno wbelt to adopt rigorous safety training programs which also encourage protec- tion of our environment, wild life and vegetation. Snowmobile clubs an[...]

9 INTRODUCTION V ehicle Identification Numbers Record your snowmobile's identif ication numbers in the spaces pro- vided. V ehicle Model Number: ____________________________________________ ________ T unnel VIN: ___________ __________________________________________ ________ (lower right side of the tunnel) Engine Serial Number: ______________[...]

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

11 SAFETY Equipment Modifications All Polaris snowmobiles have been d esigned and tested to provide safe operation when used as directed. Failu re of critical machine components may result from operation with any modification; especially those that increase speed or power . There is a significant possibility of loss of con- trol at higher speeds. W[...]

12 SAFETY Maintenance Program This snowmobile is not a toy . The information in this manual is pro- vided to aid you in its safe operation. For the safety of the operator , always make sure that the snowmobile is in excellent operating condition at all times. W e strongly recommend that the operator , as well as an adu lt, check major and vital saf[...]

13 SAFETY Safety Decals Safety and wa rning decals hav e been placed o n the vehicle fo r the oper- ator's protection. Make sure the operator und erstands the information on all decals. If any decal becomes illegi ble or comes off, cont act your Polaris dealer for a replacement. Replace ment safety decals are provided by Polaris at no charge. [...]

14 Y OUTH SECTION Know Y our Snowmobile Before you have an adult start the en gine for you for the first time, let's learn about the controls on your new snowmobile. Engine Stop Switch When the engine is running, push this b utton down to stop the engine. Pull the stop switch up befo re tryi ng to start the engine again. Throttle Lever The thr[...]

15 Y OUTH SECTION Know Y our Snowmobile Gas Cap An adult will take the gas cap of f to put gas in your snowmob ile. Never take the gas cap off. Always make sure it's tightly closed. Recoil Starter Handle Pull the recoil starter handle to star t your snowmobile. An adult will help you start it the first time. Choke Knob Y ou may need to use the[...]

16 Y OUTH SECTION Know Y our Snowmobile Let's learn more about the parts of your sn owmobile before we learn about riding. Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Tr a c k T aillight[...]

17 Y OUTH SECTION Know Y our Snowmobile Hood The hood co vers the moving and hot parts o f the engine. Always make sure both hood straps are securely latched before you start th e engine. Headlight The headlight is always on when the eng ine is running. It helps others see you when you're riding during daylight, but it 's not meant to be [...]

18 Y OUTH SECTION Know Y our Snowmobile Let's review th e 2 ways to stop your snowmobile : ST OP Push the stop switch down Pull the strap off the tether switch[...]

19 Y OUTH SECTION Pre-Ride Check Y ou're almost ready to have an ad ult start your snowmobile. But first you must do a PRE-RIDE CHECK to make sure the s nowmobile is safe to ride. Every time you want to ride your snow mobile, always have an adult help you check these things before you start the engine. n Throttle Lever Squeeze the throttle lev[...]

20 Y OUTH SECTION Pre-Ride Check n Gas Leve l Have an adult check the gas level to see if your snowmobile needs more gas. Children sh ould never op en the gas c ap or add gas. Alw ays have an adult do this. Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 in this Owner's Manual. n Oil Level Have[...]

21 Y OUTH SECTION Riding Rules Now you're ready to learn about driv ing your Polaris snowmobile. This snowmobile is not a toy . The re are so me things you can do and t here are some things you must never do. Rules are very important wh en you're driving a snowmobile. Adults have ridi ng rules, too. The rules help keep us safe when we rid[...]

22 Y OUTH SECTION Riding Rules " Always wear the right kind of clo thing when you ride your snowmo- bile. Always wear a helmet with a face shield or goggles. W ea r a warm jacket and snowpants. Make sure your clothing fits properly . T ight clothing could keep you from moving easily . Baggy clothing could hang down and get caught in the track [...]

23 Y OUTH SECTION Riding Rules " Always sit down when you drive . Keep both h ands on the ha ndlebars. Keep both feet on the running bo ards. " Never follow another snowmobile too closely . Always allow lots of space to stop your snowmobile. " Ride your snowmobile o nly where you know it's safe to driv e and where you have permi[...]

24 Y OUTH SECTION Riding Rules Learn how to use your hands and arms as signals. Use these signals to let others know when you are getting ready to tu rn or stop your snow- mobile. Read and understand y our Owner's Manual. Left T urn Right T urn Stop[...]

25 ADUL T SECTION Pre-Ride Check As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhe re to them, keeping the child's safety foremost in your m ind. Never allow the child to operate this vehi- cle without adult supervision. n Check the throttle for proper operation. See page 26. n Check t[...]

26 ADUL T SECTION Pre-Ride Check n Read and Understand Y our Owner's Manual Read and make sure the operators understand the Owner's Manual com- pletely before allowing anyone to op erate this snowmobile. It's also a good idea to review it periodically to reinforce the inform ation. It's very important to familiarize all operat o[...]

27 ADUL T SECTION Pre-Ride Check n Check the throttle safet y switch T est the throttle safety switch system on a daily basis before the vehicle is used. W ith the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration. Apply a slight amount of throttle opening. A prope[...]

28 ADUL T SECTION Pre-Ride Check n Inspect t he track Driving for extended periods of tim e with marginal lubrication could severely damage the track. Driving on ic y trails or driving when there is little or no snow are two examples of situations that would provide mar- ginal lubrication and are not recomm ended. Do not operate the snowmo- bile wi[...]

29 ADUL T SECTION Operation W arnings n Do not carry passengers This snowmobile is designed for a single operator . n Do not operate with in take silencer removed n Stay clear of track n Do not operate with drive chain gu ard removed CA UTION If the engine is o perated with the in take silencer removed, damage to the engine may oc cur . Do not oper[...]

30 ADUL T SECTION Operation W arnings n Do not touch the engine after it' s been running n Disabled operators WAR N I N G Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. WAR N I N G Safe operation of this rider-active vehicle requires good judgement and physi- cal skills.[...]

31 ADUL T SECTION Operation W arnings n Check brak e lever trav el Depress the brake lever fully . Measure the clearance between the lever and brake b lock. Clear- ance should be no more than 3/4" (1.9 cm). Excessive travel indicates a need to adjust the brake cable. Refer to the mechanical brake adjustment information on page 5 6. n Secure th[...]

32 ADUL T SECTION Operation W arnings n Check surroundings Make sure the operation area is clear of obstacles and bystanders. Some sideways movement is possible when the snowmobile first begins to move, and debris may be thrown by the track . T each the operator to check the operating area before riding. n Sit properly on t he snowmobile Operating [...]

33 ADUL T SECTION Operation W arnings n Always wear clothing designed for sno wmobiling Always make sure the operator is wearing an approved helmet and eye protection. Do not allow the child to wear loose clothing or long scarves because they can easily beco me entangled in moving parts. If your child has long hair , be sure it is always tied up se[...]

34 ADUL T SECTION Operation W arnings n Stop engine before attempt ing adjustments n Know limitations of machine and skills of driver The operator should be aware that most areas have laws governing snowmobile operation and that these laws should be foll owed. They have been establishe d for the protection of all snowmobile ride rs. Many local orga[...]

35 ADUL T SECTION Operation W arnings n Instruct a ll operators T each all young drivers to alwa ys be alert and to pay attention to the driving area ahead. When teaching inexperienced operators to ride, set up a predetermined course. Establish boundaries and make sure all oper- ators know and understand them. Make sure they know how to drive and c[...]

36 ADUL T SECTION Operation W arnings Driving Responsibly As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your m ind. Never allow the child to operate this vehi- cle without adult supervision. Drive-Away from P arked When the snowmobi[...]

37 ADUL T SECTION Operation W arnings Snow Conditions This snowmobile is designed to operate best on snow . Maneuverability is attained by the steering, skis, an d the shifting of the driver's body weight. Maximum control will be atta ined by shifting body weight. Maneuverability will change for lighter operators. If the snowmobile becomes stu[...]

38 ADUL T SECTION Operation W arnings Driving on Hills T raveling on hills is no t recommended. A ch ild may not be capable of maneuvering body weig ht as needed for operating on hills . If traveling on hills is unavoidable, teach your child to use extreme caution and obey the following proper o perating procedures. Driving Uphill Driving uphill sh[...]

39 ADUL T SECTION Operation W arnings Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL 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 [...]

40 ADUL T SECTION Component Identification Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Tr a c k T aillight Rear Suspensio n Nosepan T railing Arm F ront Bumper Rear Bumper[...]

41 ADUL T SECTION Component Identification Gas Cap Recoil Starter Handle Brake Lever Throttle Lever Engine Stop Switch Choke Knob Hood Hold-Dow n Strap[...]

42 ADUL T SECTION Break-In P eriod Engine Break-In The break-in period for yo ur new snow mobile is defined as t he first ten hours of operation, or the time it take s to use the first two tanks ful l of gasoline. No single action on your part is as important as a proper break- in period. Careful treatm ent of a new engine will result in more effic[...]

43 ADUL T SECTION Operation Fu e l When refueling, use eith er leaded or un leaded gasolin e with a minimum pump octane number of 87=(R+ M)/2 octane. Do not use E-85 fuel. WAR N I N G Gasoline is highly flammable and explosive und er certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engin[...]

44 ADUL T SECTION Operation Speed/Performance Regulation As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your m ind. Never allow the child to operate this vehi- cle without adult supervision. Y ou can regulate the speed and accelerati[...]

45 ADUL T SECTION Operation Starting the Engine Never start the engine before performing the Pre-Ride Check. See pages 19 and 25. 1. Pull the engine stop switc h up to the RUN position. 2. Do not use the choke when startin g a warm engine. If the engine is cold, pull the choke lever completel y out to the FULL ON position. NOTE: Do not ap ply throt[...]

46 ADUL T SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the snowmobile in the event of an emergency . See pages 14 and 27 for more information about the engine stop switch and throttle safety switch. Daily Storage At the end of each ride, park the snow- mobile on a level surface. Support the rear wit[...]

47 ADUL T SECTION Operation Pre-Ride Warm-Up Always warm up the engine, drive tr ain an d track before operating the snowmobile. Support the rear with an appropriate track stand. The track should be suspend ed approximately 4 I (10 cm) off the ground. 1. Star t the engine. Allow it to idle for two to three minut es. 2. Engage the drive sy stem abru[...]

48 ADUL T SECTION Emission Control Information Any qualified repair shop or qualifie d 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 inform[...]

49 ADUL T SECTION Maintenance Polaris Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 94. The recommende d maintenance sc hedul e fo[...]

50 ADUL T SECTION Maintenance Periodic Maintenance Chart The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . ITEM SEE PA G E DAIL Y WE EKL Y O[...]

51 ADUL T SECTION Maintenance Periodic Maintenance Chart ITEM SEE PA G E DAIL Y WE EKL Y OR BEFORE EXTENDED PERIOD OF OPERA TION 50 HRS 100 HRS 150 HRS Check track alignment 65 X Check track condition 67 X Check drive chain tension 59 X Check and tighten any loose suspension mounting bolts 72 X Tighten ski saddle and spindle bolts if loose -- X Che[...]

52 ADUL T SECTION Maintenance Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section beginnin g on page 80 for recom- mended spark plug ty pe and gap. Spark plug condi[...]

53 ADUL T SECTION Maintenance Spark Plugs 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. NOTE: The tip should n ot be white. A white insulator tip in dicates overheating[...]

54 ADUL T SECTION Maintenance F uel V alve/F uel Lines Inspect the fuel valve and the fuel lines regularly . Carefully check the system's fuel line condition after periods of storage. Normal deteriora- tion from weather and fuel compounds can occur . Replace any worn or damaged components. Exhaust System At approximately 50 hours, ch eck th e [...]

55 ADUL T SECTION Maintenance Carburetor Proper carburetor adjustment is cri tical, since a mixture too lean (t oo much air , too little fuel) will result in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failure. A le an mixture can be the result of fuel l[...]

56 ADUL T SECTION Maintenance Brake Lever T ravel Firmly depress the brake lever . Measure the clearance betwe en the lever and brake block. If clearance is more than 3/4" (19 mm), adjust the brake cable as outlined below . Brake Cable Adjustment If proper adjustment cannot be achi eved using the following methods, check the brake band. If the[...]

57 ADUL T SECTION Maintenance Brake Cable Adjustment 4. Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and that all parts are mounted securely . Tigh ten hardware as required. 5. T ighten the adju ster jam nut and slide the rubber protectors onto the ad[...]

58 ADUL T SECTION Maintenance Throttle Cable Lubrication W ith the engine off, lubricate the throttle cable occasionally . T urn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate the choke intermittently before turning the en[...]

59 ADUL T SECTION Maintenance Chain T ensioner Inspect the chain. Proper deflection is one inch (25 mm). Adjust the chain if deflection is incorrect. 1. Loosen the nut on the chain tensioner . 2. Raise the tensioner until the co rrect deflection is attained. 3. T ighten the nut to 15-18 ft. lb s. (20-24 Nm). NOTE: When the chain has stretched to wi[...]

60 ADUL T SECTION Maintenance Driveline Lubrication NOTE: Driveline noise is normal for this vehicle. T o ensure long life of the snowmobile 's driveline, lubricate as follows: • Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. • Lubricate Point B every 10 hours of operation with aeros[...]

61 ADUL T SECTION Maintenance Engine Oil Oil Recommendations Polaris recommends the use of Perfo rmance Synthetic 4-Stroke oil (PS- 4 or PS-4 Plus) for this en gine. PS-4 has been specially formulated for use in Polaris 4-cycle snowmobile en gines. It's a fully synthetic, high performance, multi-viscosity oil desi gned to provide t he ultimate[...]

62 ADUL T SECTION Maintenance Engine Oil Oil Change 1. Support the rear of the snowmobile slightly of f the ground with an appropriate snowmobile support. 2. Place a drain pan under the drain plug. NOTE: The drain plug is lo cated under the bulkhead and in front of the engine. 3. Remove the drain plug. 4. Remove the dip stick and wipe it dry with a[...]

63 ADUL T SECTION Maintenance T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. 1. Operate the snow- mobile to warm up the track. 2. S top the engine. 3. Support the rear of the snowmobile slightly off t he ground with an appropriate snow- mobile support. 4. Hang a 10-pound (4.5 kg)[...]

64 ADUL T SECTION Maintenance T rack T ension Adjustment 1. Loosen the rear idler shaft bolt. 2. T ighten or loosen the track adjus ting screws to provide equal adjust- ment on both sides of th e track. 3. Repeat the measurement on the other side of the track. NOTE: Check tension more frequen tly when the machine is new . 4. Star t the engine and s[...]

65 ADUL T SECTION Maintenance T rack Alignment Check track alignment at the interval s outlined in the periodic mainte- nance chart beginning o n page 50. Make sure the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Support the rear of the snowmobile slightly off the g[...]

66 ADUL T SECTION Maintenance T rack W arm Up After storing your snowmo bile outside overnight, warm up the track before driving the snow- mobile. This reduces drive clutch wear . 1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. 2. Star t the engine. 3. Abruptly engage the clutch, allowi ng the t[...]

67 ADUL T SECTION Maintenance T rack Inspection Check track condition at the intervals outlined in the periodic mainte- nance chart begi nning on page 50. 1. Support the rear of the snowmobile slightly off the ground with an approp riate snowmobile support. 2. Rotate the track by han d to check for wear or damage. 3. Carefully examine the track alo[...]

68 ADUL T SECTION Maintenance Slider Replacement Polaris rail slides have a wear limit indicator groove to indicat e the minimum permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Fail- ure to do so may result in perma- nent damage to the track or rails. T rack Lubricati[...]

69 ADUL T SECTION Maintenance Steering Inspection Each week, or before a long ride, check all steering sy stem fasteners. T ighten any loose fasteners. The star s in the illustration below indicate fastener locations. Steering Adjustment W ith the handlebars in a straight ahead position, and with vehi cle weight compressing the suspension, measure [...]

70 ADUL T SECTION Maintenance Handlebar Adjustment 1. Slide the ha ndlebar pad upward to access the adjuster bolts. If additional room is required, unzip on e of the handlebar pad zippers and roll the pad to the side. 2. Remove the upp er flange nut and carriage bolt. 3. Loosen the lower flange nut only enough so the bracket can move freely . 4. Po[...]

71 ADUL T SECTION Maintenance Ski Skags The skag is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain. Check skags weekly to maintain po sitive steering characteristics. Replace skags wh[...]

72 ADUL T SECTION Maintenance Lubrication Recommendations Suspension T o maintain rider comfort and to reta rd wear of the pivot shafts, l ubri- cate the suspension pivot shafts with Polaris Premium All Season Grease several times during the seaso n and again before summer storage each year . Lack of lubrication will result in reduced performance a[...]

73 ADUL T SECTION Maintenance Lubrication Recommendations Inspect and lubricate all greaseable co mponents at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Controls and Linkage Lubricate all bushings and tie rod ends with a light coat of oil or grease. Remove the spindle shafts and lubri cate the bush ings on the to[...]

74 ADUL T SECTION Maintenance W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing clot h, cleaning the up[...]

75 ADUL T SECTION Maintenance Storage Off season or extended storage of yo ur snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many compon ents. Fog the Engine 1. T reat the fuel system with Po laris Carbon Clean. See page 76. 2. Support the front end of the machine so the engine is level or til[...]

76 ADUL T SECTION Maintenance Storage Stabilize the F uel Proper off-season preparation of the en gine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage. See page 82 for the part numbers of Polaris produ cts. 1. Fill the fuel tank with fresh fuel. 2. Add Polaris Carbon Clean Fuel T r[...]

77 ADUL T SECTION Maintenance Storage T rack and Suspension Support the rear of the snowmob ile slightly off the ground with an appropriate snowmobile support. This will allow the track to hang freely . Elevate the front end of the machine and place blocks securely un der it to remove tension from the shocks and springs. This will minimize fatigue [...]

78 ADUL T SECTION Maintenance T ransporting the Snowmobile Whenever the snowmobile is transp orted the following me asures should be taken: 1. T urn the fuel valve off. 2. Be sure the fuel cap is installed correctly . 3. Always tie the snowmobile to the transporting unit securely using suitable straps. F all T une-Up T o obtain maximum performance [...]

79 TROUBLESHOOTING Engine T urns Over , F ails to Start Contact your Polaris dealer for service if you're unable to identify solu- tions using the following chart. Possible Cause Solution T ether switch not engaged In stall tether switch/strap Engine stop switch not on Pull stop switch up to RUN position Throttle safety switch malfun ction See[...]

80 SPECIFICA TIONS Capacities and Dimensions Body Style Mini Indy Rider/Weight Capacity 1/140 lbs. (63.5 kg) maximum Dry Weight 147.5 lbs. (67 kg) F uel T ank Capacity .5 gal. (1.9 l) Engine Oil Capacity 20 oz. (.6 l) Height 31 in. (78.7 cm) Length 75 in. (190.5 cm) Width 34 in. (86.4 cm) T rack Length 69 in. (175.3 cm) T rack Width 10 in. (25.4 cm[...]

81 SPECIFICA TIONS Carburetor Jetting AMBIENT TEMPERA TURE AL TITUDE Meters (F eet) Below -25 ° F (-31 ° C) -30 ° to -10 ° F (-34 ° to -23 ° C) -15 ° to +5 ° F (-26 ° C to -15 ° C) 0 ° to +20 ° F (-18 ° to -7 ° C) +15 ° to +35 ° F (-9 ° to +2 ° C) +30 ° to +50 ° F (-1 ° to +10 ° C) +45 ° to +65 ° F (+7 ° to +18 ° C) Above [...]

82 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal.) 2876244 Performance Synthetic 4- Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4- Stroke (PS-4 Plus) Oil (gal.) Gearcase/T[...]

83 WA RRANTY Service and W arranty Information Obtaining Service and Warranty Assistance Read and understand the service data an d the Polari s warranty informat ion con- tained in this manual. Cont act your Polaris dealer for replacement parts, service or warranty . Y our dealer receives freque nt updates on cha nges, modifications and tips on sno[...]

84 W ARRANTY Service and W arranty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft . A. In addition to noti fying the pr ope r law enforcement officials, the ow[...]

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

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

87 WA RRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to d elivery may[...]

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

89 WA RRANTY Polaris Second Y ear Engine Service Contract Coverage Coverage for second year en gine failures due to defects in materials and workmanship will be determined by Polaris in its sole 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 deductible p[...]

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

91 WA RRANTY Exported V ehicles How to Get Service In the Country where you r vehicle was purchased: W arranty 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 a rranty or Service Bulletin repairs may be requested from any authorized Polar[...]

92 W ARRANTY U.S.A. EP A Emissions Limited Warranty This emissions li mited warranty i s in addition to t he Polaris standard limite d warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Environment[...]

93 WA RRANTY U.S.A. EP A Emissions Limited Warranty The exclusive remedy for breac h of this limited warranty shall be, at the excl usive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN THIS LI MITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF TH[...]

94 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wi th an accurate log of maintenance and servi ces performed on the snowmobile. DA T E HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 50 100 150[...]

95 MAINTENANCE L OG DA T E HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

96 INDEX A Air Pollution . . . . . . . . . . . . . . . . . . . 7 B Bearings . . . . . . . . . . . . . . . . . . . . . . 73 Brake Cable Adjustment . . . . . . . 56-57 Brake Lever . . . . . . . . . . . . . . . . . . . 14 Brake Lever Travel . . . . . . . . . . . . . 56 Break-In Period . . . . . . . . . . . . . . . . 42 C Carburetor . . . . . . . . . .[...]

97 INDEX S Safety Decal s . . . . . . . . . . . . . . . . . . 13 Safety Symbo ls . . . . . . . . . . . . . . . . . 10 Signal Words. . . . . . . . . . . . . . . . . . . 10 Skag Replace ment. . . . . . . . . . . . . . . 71 Ski Skags . . . . . . . . . . . . . . . . . . . . . . 71 Slider Replac ement . . . . . . . . . . . . . . 68 Snow and Ice Build-Up[...]