Polaris 500 IQ Shift manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g 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 la test news, new product introduc- tions, upcoming events, car eer opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- at[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris 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 components, some minor discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful info rmation for own ers 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 snowmo bile'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 b lank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.[...]

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourag e governments to adopt rigorous safety training pro - grams that encourage protection of ou r environment, including wildlife and vegetation. Snowmobile clubs and o ther organizations are wo rking together to pro- te[...]

6 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. W ARNING A W ARNING indicates a [...]

7 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 62 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. Driving a snowmobile requires your full atten tion. DO NOT drink alcohol or use drugs or medications before or whil[...]

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

9 SAFETY Operator Safety Riding App arel Be prepared, be warm and b e 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! A void wearin g loose clothing or long scarves, which can become entangled in moving parts and cause serious injury . Helmet W eari[...]

10 SAFETY Operator Safety Survival Prep aration For your safety , always ri de in a group of other snow mobilers. Always tell someone where yo u're going and how long you ex pect to be gone. If it isn't possible to ride with others , and you must travel into remote areas, always carry survival equipm ent that's appropriat e to the co[...]

11 SAFETY Operator Safety Disabled Operators Safe operation of this rid er-active vehi cle requires good judgement and physical skills. Operators with cogn itive or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Rider Cap acity Y our Polaris snowmobile is designed for a single rider [...]

12 SAFETY Operator Safety Driver Awareness 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 d[...]

13 SAFETY Operator Safety A valanches Snowmobilers should always be properl y trained and equipped before traveling in mountainous terrain: • T ake an av alanche cl ass • 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 sn[...]

14 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may interf ere with the steering of your machine, resulting in serious injury or dea th. Keep the underhood area free of snow and ice. Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right stee[...]

15 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 engaged, allow ing the engine 's compression to help slow the machine and keep it fro m rolling freely downhill. W ARNING! When driving on long d ownhi[...]

16 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 machine rol l-over , causing seri ous i njury or deat h. Use caution and good judgement when driving in hilly te rrain. Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, [...]

17 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires op eration without a belt must be performed by your dealer . Operation of th e engine with the belt remo ved may result in injury or damage to the engine. Int ake Silencer Do not operate the engine with the intake silencer or fil[...]

18 SAFETY Operator Safety Inadequate Snow Conditions W ARNING! Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irre versible track damage and lead to serious injury . Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled mo dels, coo ling for the engine, adequate snow cov[...]

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

20 SAFETY Operator Safety Windchill/T emperature Chart s 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 Speed 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 hav e been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this ma nual differ from the decals on your snow mobile, always read and follow the instructions of the de[...]

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. Entanglement with the track or a fall from seat back may result in seve re injury or death. "No Passenger" W arning The "NO P ASSENGER" warning decal is on the console below t[...]

23 SAFETY Safety Decals and Locations Reverse W arning The reverse warning decal is located on the upper console: W ARNING Reverse operation, even at lo w speeds, can cause los s of control resulting in serious injury or death. T o avoid loss of con trol, always: • Look behind before and while backing up. • A void sharp tu rns. • Shift to or [...]

24 SAFETY Safety Decals and Locations Operation W arning • T o avoi d serious inj ury or death, read and understand all warnings and the Owner's Manual before oper ation. If manual is missing, con- t act a Polaris de aler for a replacement. • This vehicle is capable of high speeds. Buried object s or uneven terrain can cause lo ss of contr[...]

25 FEA TURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. T aillights 7. Re ar Bumper 8. Sn ow Flap 9. Co nsole S torage Compartm ent (if equippe d) 10. Suspension 11 . Tr a c k 12. Skis 13. Nosepa n 14. Front Bumper (do not use for pu lling or dragging the snowmobile) 5 11 2 3 4 10 8 12 13 14 1 9 7 6[...]

26 FEA TURES 1. Fuel Filler Cap/Dipstick 2. Recoil St arter Handle 3. Reverse I ndicator 4. Headlight Adjuster 5. S peedomet er 6. En gine S top Switch 7. Ch oke Lever 8. Ig nition Switch 9. Brake Lever 10. Parking Br ake 1 1. Handlebar Grip W armer Switch 12. Thumbwarmer Switch 13. Electronic Reve rse Button 14. Headlight Dimmer Switch 15. Throttl[...]

27 FEA TURES Fuel V alve The fuel valve is located under the hood. Tu rn the fue l valve off when- ever the snowmobile is stored or parked. 1. T urn the valve clockwise to turn off the fuel supply . 2. T urn the valve coun ter-clock- wise to turn on the fuel supply . Adjust able Headlight s Adjust the headlight beam by moving the adjuster to the le[...]

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 ri der to rider , depending on rider weight, vehicle speed, riding style, an d trail conditions. W e recommend starting with factory settings and [...]

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 s hock spring preload[...]

30 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension des igns and adjust ments involve a compromise, or t[...]

31 THE PERFECT FIT Rear Suspension Adjustment s Suspension Performance Tip s • Rider weight usually determines th e position at 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 se tup. These adjustments are easy to make, involv e very little time [...]

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 re ar suspension at full extension. Tip : The rear bumper may need [...]

33 THE PERFECT FIT IQ Rear Suspensi on 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. Differen[...]

34 THE PERFECT FIT IQ Rear Suspensi on Adjustment s Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension coupling, thes e torque arms could mo ve independently of each other . Rear su spension coupling links th e movement of the f[...]

35 THE PERFECT FIT IQ Rear Suspensi on Adjustment s Suspension Coupling Rear T o Front Coupling and the Rear Rear Scissor Stop (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 ou nt of indepen- dent movement be tween the rear torque and the front torque arm. Adjusting [...]

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

37 THE PERFECT FIT T raction Product s n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Inspect skags frequently . W orn skags may reduce steering and braking control on hard-packed snow a nd ice. Replac[...]

38 THE PERFECT FIT Handlebar Adjustment s When making handleb ar adjustments, always be sure the handlebars, brake lever and throttle lever operat e smoothly and do not contact the fuel tank, windshield o r any other part of the vehicle when t he handle- bars are turned fully to the left or right. Handlebar Position Follow these steps to adjust han[...]

39 THE PERFECT FIT Handlebar Adjustment s Handlebar Angle Follow these steps to adjust handle bar angle at the handlebar blo ck. 1. Remove the handlebar cover . 2. Loosen the four upper adjuster bl ock 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 .[...]

40 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmob ile. Procedures are outlined on the ref- erenced pages. Look for a checkmark ( n ) on the refere nc ed pages to locate the pre-ride inspection items. Item See Page Drive Belt Condition 83, 85 S teering Syst[...]

41 PRE-RIDE INSPECTIONS Before St arting the Engine W ARNING! W orn, damaged , or malfunctioning componen ts 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 y[...]

42 PRE-RIDE INSPECTIONS Before St arting the Engine n Brakes Always check the following items fo r 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 I (1.3 cm). A smaller distance indicates low brake fluid leve l or air in the hydraulic system. Refer to the b[...]

43 PRE-RIDE INSPECTIONS Before St arting the Engine n Parking Brake Lever Lock Use the parking brake lever lock onl y when you want the machine to remain stationary; for ex ample, 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 [...]

44 PRE-RIDE INSPECTIONS Before St arting the Engine n Steering System 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, remove ice and snow build-up that may be obstru cting the steering linkage. n T rack W ARNING! Operating the[...]

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

46 PRE-RIDE INSPECTIONS S t art the Engine and Check Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without check- ing all componen ts to be sure of proper operation. See Before Startin g the Engine beg inning on page 41. n Engine S top Switch Check the auxiliary shut[...]

47 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the tr ansmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the fuel valve on. See page 27. 2. T urn the key to the ON position. 3. Pull the engine stop switch up to the[...]

48 OPERA TION Emergency S topping 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. Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebui[...]

49 OPERA TION Engine Break-In 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 t he 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 machi ne and the moving track. Never hold the snowmobile up or stand be hind it while warmin g up the track. D o not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear s[...]

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

52 OPERA TION Fuel Y our Polaris en gine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal of variability in the quality of the 87 octane gaso line available across the country , so we encourage the use of pr emium fuel wh en possible. Do not use fuel containing mor e than 10% ethanol (i[...]

53 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. Add oil before further operation of the snowmobile. See page 49 for oi l recommendations. Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss o[...]

54 OPERA TION Carburetion Proper carburetor adjustment is c ritical. A lean mixture (too muc h air , too little fuel) may result in piston bu rning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by thin gs like fuel[...]

55 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e af fect air density , which is the amount of oxygen avai lable for combustion. In low ele vations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carbure tors are calibrated for a n a ltitude of [...]

56 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( + ) to groun d out the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restart- ing. 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 throt[...]

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 death . If the throttle lever does not work properly , DO NOT st art the engine. If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switc[...]

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

59 OPERA TION Electronic Reverse (PERC t ) Engaging Reverse 1. S top 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 lig[...]

60 OPERA TION To w i n g Do not use the fr ont bumper to pull or dr ag the snowmobile. The fro nt bumper is not designed for this type of use and may deta ch 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 p roper hitch functions. W ARNING! Ob[...]

61 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-[...]

62 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 1 13. The recommended maintenance schedul e on your snowmobil[...]

63 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y o u may need to increase fre quency based on ridi ng conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten,[...]

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 R 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 Season Grease at 500 miles (800 km) initially , every 100 0 miles (1600 km) after that, and before off-season storage e ach year . Lack of lubrication will adversely affect you[...]

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 approximate ly two pumps. Do not use more t han four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. W ith the engine off, turn[...]

68 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l 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[...]

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 su rfaces on the drain plug and the o[...]

70 MAINTENANCE Spar k P l u g s It’ s very important to use the corre ct spark plug for you r 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. Change t he spark plugs every 2000-2500 miles (3200- 4000 km). NOTICE: A spark plug[...]

71 MAINTENANCE Spar k P l u g 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 overheatin[...]

72 MAINTENANCE Int ake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose po wder 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 ca[...]

73 MAINTENANCE Fuel Filter/Fuel Lines See your Polaris dealer for replacem ent of the unde r-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deteriorat ion or damage. Always check fuel line condition after periods of sto rage. Normal dete- rioration from weather and fue l compounds may occur . Replace [...]

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 correc t for your elevation. It's your dealer's responsi bility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with incorrect jetting can result i[...]

75 MAINTENANCE Carburetor W a ter/Sediment T rap Most Polaris snowmobiles contain pa tented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination. W ARNING! When draining the traps, fuel sp illag[...]

76 MAINTENANCE Drive Chain T ension Check drive chain tension 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. Fing[...]

77 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect brake lever travel before each use of the snowmobile. See page 42. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ). A kit is available for replacing brake pads. S ee your dealer . W ARNING! Brake failure during operat[...]

78 MAINTENANCE Brakes Brake Fluid W ARNING! Af ter opening a bottle of brake fluid, always discard an y 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 th[...]

79 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. W ARNING! Operating the vehicle 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 operat[...]

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

81 MAINTENANCE Light s T aillight/Brakelight Replacem ent 1. Remove the screws securing th e taillight lens. Remove the lens. 2. Push the bulb inward and turn it counterclockwise 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 engageme nt or an unusual vibration or shift pattern, see your dealer immediately . Do not operate [...]

83 MAINTENANCE Clutch System n 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 exce ssive looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 103. For[...]

84 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip : T o ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identificatio n numbers so that you can read them. If required, separate the sheaves as outl ined in th[...]

85 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 apply downward pressure while measuring at point 2. This measurement should b e 1 1/4 I (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 opera te 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 of f the ground. 2. Rot[...]

87 MAINTENANCE T rack Maintenance T rack Lubrication W ARNING! Operating with insufficient lubr ication be tween the rail slide and track guide clips can cause track failure, loss of vehicle contro l and loss of braking ability , which can result in seri ous injury or de ath. Avoid operating for extended periods on ice and other surfac es that have[...]

88 MAINTENANCE T rack Maintenance W ARNING! Moving p arts 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 measur ement or adjustments with the engin e running. T rack T ension T rack adjustment is critical for prop er handling. Always ma[...]

89 MAINTENANCE T rack Maintenance T rack T ension 4. Check for specified slack between th e 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 th e track adjus ting screws to provi[...]

90 MAINTENANCE T rack Maintenance n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track of f the ground. 2. S tart the engine and apply a small amount of throttle unt il the[...]

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

92 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustmen t. See your Polaris deale r . W ith the handlebars in a st raight ahead position, and with veh icle weight compressing [...]

93 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 nece ssary to add track st uds to ma intain proper vehicle con- trol while turning on hard-packed snow or ice. W ARNING! W orn skis and/or skags [...]

94 MAINTENANCE S teering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove ( + ). Do not operate the snowmobile if slide thickness measures les s than 7/16 I (1.1 cm). Suspension Maintenance n Pre-Ride Suspensio[...]

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

96 MAINTENANCE Extended Storage Bearings Grease the jacks haft and drive sha ft clutch side bearings w ith Polaris Premium All-Season Grease or a simi lar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive b elt and store in a co ol dry locati on. Do not lubricate clutch components, except the driven clutch sh aft bu[...]

97 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured awa y from sharp edges, steering linkage, moving parts, and hot exhaust pa rts. T rack and Suspension Moderate track tension should be maintained during summer storage. The machine should be supp[...]

98 POLARIS PRODUCTS Part N o. Description Engine L ubricant s 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2875035 Premium Synthetic Ble nd (Blue) 2-Cycle Oil (qt./.95 l) 2875036 Premium Synthetic Blend (B lue) 2-Cycle Oil (gal./3.8 l) 2875037 Premium Synthetic Blend (Blue) 2-Cycle Oil (2.5 gal./9.5 l) 2874438 VES II Synthetic 2-Cycle Oil (qt./.95 l[...]

99 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • Disassemble drive clutch to inspect shift weights for wear and [...]

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

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

102 TROUBLESHOOTING IQ 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 stif fer optional spring (see your dealer). • Revalve rear track s hock (see your dealer). Rides too stiff in rear • Check for binding[...]

103 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the mach ine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the ma chine in extremely cold weather and warm it up. Break machine loose fr[...]

104 W ARRANTY Service and W a rranty Information Obt aining Service and W arranty Assistance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, ser- vice or warranty . Y our dealer recei ves frequent updates on changes, modifications and tip s on[...]

105 W ARRANTY Service and W a rranty Information Polaris Anti-Thef t System The Polaris anti-theft system (P A TS) monito ring 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 notifying the proper law enforce ment officials, the ow[...]

106 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Po laris snowmobile ag ainst defects in material or workmanship. This warranty cove rs the parts and labor charges for r epair or replacement of defective parts that are cove red by th is warranty [...]

107 W ARRANTY Limit ations of warranties and re medies 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 A R- RANTIES NOT ST A TED IN THIS W ARRANTY . Som[...]

108 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required veh icle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to delivery ma[...]

109 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. The free Second Y ear E ngine Service Contract is honored by all authorized Polaris snow[...]

110 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 LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

111 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty is in addition to the Polaris standa rd limited 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. Environmen[...]

112 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN THIS L IMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH OF[...]

113 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 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.[...]

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

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

11 6 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 37 Adjustabl e Headlights . . . . . . . . . . . 27 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Altitude Setti ng . . . . . . . . . . . . . . . . 59 Avalanches . . . . . . . . . . . . . . . . . . . . 13 B Bearings . . . . . . . . . . . . . . . . . . . . . . 96 Before Starting t[...]

11 7 INDEX I Ice and Snow Build- up . . . . . . . . . . . 14 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 IFS Adjustme nt Options . . . . . . . . . . 28 IFS Components . . . . . . . . . . . . . . . . 28 Inadequate Snow Conditions . . . . . . 18 Intake Filters . . . . . . . . . . . . . . . . . . . 72 Intake Silencer . . . . . . . . .[...]

11 8 INDEX T Taillight/Brakelight Replacement . . 81 Throttle Cable . . . . . . . . . . . . . . . . . 67 Throttle Lever . . . . . . . . . . . . . . 41, 57 Throttle Safety Switch . . . . . . . . 41, 56 Torque Stop . . . . . . . . . . . . . . . . . . . 85 Torsion Spring Preload, IQ . . . . . . . 33 Towing . . . . . . . . . . . . . . . . . . . . . . .[...]