Polaris 800 Dragon Switchback 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8[...]

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5 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. Some of the illustrations and photos used in this manual are general rep- resentations. Y our model may differ . Follow the maintenance program out[...]

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation. Snowmobile clubs and o ther orga[...]

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

8 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 [...]

9 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 79 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[...]

10 SAFETY Operator Safety Stay 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[...]

11 SAFETY Operator Safety Riding Apparel Be prepared, be warm and be com- fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly . See the chart on page 22. W ARNING! A void wearin g loose clothing or long scarves, which can become entangled in moving parts and cause serious injury . Helmet W earing [...]

12 SAFETY Operator Safety Disabled Operators Safe operation of this 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. Survival Preparation For your safety , always ri de in a group of other [...]

13 SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only . A decal on the console of these mode ls indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for on[...]

14 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[...]

15 SAFETY Operator Safety Avalanches 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 sno[...]

16 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[...]

17 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[...]

18 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, [...]

19 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 the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter[...]

20 SAFETY Operator Safety Inadequate Snow Conditions 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 cover is a requirement for op eration of your snowmobile. NOTICE: Driving in too little snow will resu lt in excessive wear and damage to the slide rail, [...]

21 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[...]

22 SAFETY Operator Safety 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 T emperature[...]

23 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[...]

24 SAFETY Safety Decals and Locations Hot Surface W arning The hot surface warning is located near the rear of the tunnel: WARNING HOT SURF ACE - DO NOT TOUCH Burn may res ult. Entire top of tunnel ma y be hot. Install only accessories s pecifi- cally approved for this model by Pol ar i s. T rack W arning The track warning decal is at the rear of t[...]

25 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console beside the steering post: WARNING Reverse operation, even at low speeds, can cause lo ss of control resulting in seriou s injury or death. T o avoid loss of control, always: • Look behind before and while backin g up. • Avoid sharp turns . [...]

26 SAFETY Safety Decals and Locations Operation W arning • T o avoid serious injury or death, read and unde rstand all warnings and the Owner's Manual before oper ation. If manual is missing, con- tact a Polaris dealer for a replac ement. • This vehicle is capable of high speed s. Buried objects or uneven terrain can cause lo ss of control[...]

27 FEA TURES Not all models are equipped with all features shown. 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper (do no t use for pulling or dragg ing the snow- mobile) 4. Hood 5. Headlight 6. Windshield 7. Handlebar 8. Operator Seat 9. T aillight 10. Rear Bumper 11. Snow Flap 12. Suspension 13. T r ack[...]

28 FEA TURES Not all models are equipped with all features shown. 1. Fuel Filler Cap 2. Ig nition Switch 3. M FD Gauge 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Hood Hold Down Straps 8. Parking Brake Lock 9. Ha ndlebar Grip Wa r m e r Sw i t ch 10. Thumbwarmer Switch 11. Electro nic Reverse Butt on 12. Multi- F unction D[...]

29 FEA TURES Cargo Area The maximum weight capacity for the cargo area is 15 lbs. (7 kg). Install only accessories specifically approved for this model by Polaris. Always secure cargo before operating. Do not exceed the carg o area weight limit. Adjustable Headlights Adjust the headlight beam by moving th e adjuster to the left or right. Detonation[...]

30 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog (if equipp ed) 2 Digital Gauge 3 CHECK ENGINE Indicator (carb models) 4 Low Oil Indicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Item 1 RPM or Speed Altitude (if equipp ed) Service Interval 2 Electrical [...]

31 FEA TURES Instrumentation MFD Settings W ith the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( + ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measurement. While viewing a screen that displays measure[...]

32 FEA TURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle thro ugh the three MFD programs: Per- formance, Engine and History . Each program will remain in the display until another is selected. TIP: The analog will always display either MPH or engin e RPM (whichever set- ting is selected) regardless of the display pro[...]

33 FEA TURES Instrumentation MFD Digital Display Programs T rip Settings Tr i p 1 a n d Tr i p 2 ar e odometers used to check fuel mileage or to keep track of distance traveled. 1. T o reset a trip odometer to zero, enter the T rip 1 or T rip 2 display . 2. Press and hold the SET button for two seconds. If the snowmobile is equipped with an electro[...]

34 FEA TURES Instrumentation MFD Digital Display Programs Performa nce Program Clock Setting 1. While in the CLOCK display , press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour , or press and hold the SET button to advance the hour once every 0.2 sec onds. 3. Press the MODE [...]

35 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram The Engine Program automatically di splays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped w ith altimeter sensor and ambient air temperature sensors, altitude and ambi ent air temperature will[...]

36 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. TIP: Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement. [...]

37 FEA TURES Instrumentation MFD Digital Display Programs History Program The History Program automatically di splays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, maximum engi ne rpm or the current service interval set- ting. The gauge automatically logs[...]

38 FEA TURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gaug e provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG[...]

39 FEA TURES Instrumentation MFD Battery Replacement (models with clocks) If the clock function of the MFD isn't working properly , replace the battery . Replacement batteries are available from your dealer . 1. Remove the plenum from the under- side of the hoo d. 2. Locate the black battery compart- ment. It has a red wire and a brown wire wi[...]

40 FEA TURES Instrumentation MFD Battery Replacement (models with clocks) 6. Install a new battery with fingers only . 7. Seal the end of the battery compar tmen t using high stre ngth double- sided tape between the two compar t ment halves or high strength single-sided tape around the outside of the compartment. 8. Make sure the taped seam of the [...]

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

42 THE PERFECT FIT F ront Suspension Adjustments 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 l eft and right sides of th e machine are at the same adjustment. T o change front s hock spring prelo[...]

43 THE PERFECT FIT F ront Suspension Adjustments Shock Compression Damp ing (Premium Shocks) T urn the adjuster to make adjustments to the compression damping. When adjusting, we recomm end that you turn the adjuste r only one click, then test ride. Always adjust bot h shocks equally . The standard setting is 4 clicks from the softest position. •[...]

44 THE PERFECT FIT Rear Suspension Adjustments 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 [...]

45 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • 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 or[...]

46 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) T o set up the rear suspension tor- sion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. The rear bumper may need to be [...]

47 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) T o determine sag, common ly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). If the measu red sag is incorrect, adjust the FRA position and/or rear torsion spring preload. TIP: This is only an initial setup, an d final spring preload may va[...]

48 THE PERFECT FIT Rear Suspension Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark p lug tool. Adjust ment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Different ra[...]

49 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Posi tion (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling . If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. T ighten the straps to increase ski pressure.[...]

50 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Compression Damping (Pre mium Shock) T urn the adjuster on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster one click, then test ride. • T urn the adjuster clockwise for a stiffer[...]

51 THE PERFECT FIT Rear Suspension Adjustments 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 front [...]

52 THE PERFECT FIT Rear Suspension Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) 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 of in depen- dent movement be tween the rear torque and the front torque arm. Adjusting the RRSS either allows [...]

53 THE PERFECT FIT Rear Suspension Adjustments W eight T ransfer During Acceleration The preferred method for control- ling weight transfer during accel- eration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner- i[...]

54 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the handlebar forward or rearward to the desired position. 3. T ighten the bolts. Handlebar Angle 1. Loosen the four bolts on the top of the adjuster block. If n[...]

55 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury t[...]

56 THE PERFECT FIT T raction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction prod ucts on your snowmo bile. T rack warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installation or t [...]

57 THE PERFECT FIT T raction Products 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. Use carbide skags with studded tracks to help maintain prop er vehicle steering and control. See page 1 13. If your [...]

58 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 refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See P age Drive Belt Condi tion 102 Steering System 6[...]

59 PRE-RIDE INSPECTIONS Before Starting 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 prop er operation. W ARNING! Operating the vehicle with worn , damaged, or malfunctioning components could result in seri[...]

60 PRE-RIDE INSPECTIONS Before Starting 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 br[...]

61 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking 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 [...]

62 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System 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 ful[...]

63 PRE-RIDE INSPECTIONS Before Starting 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 an[...]

64 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never en gage the starter when the engine is running. Never start the engine with out checking all ve hicle components to be sure of proper operatio n. See Before Starting the Engine beginning on pa[...]

65 OPERA TION Starting 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 key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. If equipped with electri[...]

66 OPERA TION 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 rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection o il for each five gal- lons of fuel. This, in addition to th e lubrication supplie d by the injection system, will assure prop[...]

67 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 71. 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 This s[...]

68 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[...]

69 OPERA TION Fu e l 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 ope[...]

70 OPERA TION Fu e l Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not us e lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). NOTICE: Operating with obstructed fuel syst ems will result in s[...]

71 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 67 for oi l recommendations. Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss o[...]

72 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( + ) to ground out the ig nition 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 throttl[...]

73 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[...]

74 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit[...]

75 OPERA TION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Da mage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed . • Shift to or from reverse only when the snowmobile is stopped an[...]

76 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[...]

77 OPERA TION Daily Storage 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. To w i n g Do not use the fr ont bumper to pull or dr ag the snowmobile. The fro nt bu[...]

78 MAINTENANCE 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 informa- [...]

79 MAINTENANCE P olaris Recommended Mainte nance 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 133. The recommended maintenance schedul e on your snowmobi[...]

80 MAINTENANCE P eriodic Maintenance Interval T able 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 . I - Inspect (clean, adjust, tighten, [...]

81 MAINTENANCE P eriodic 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 96 II II Brake Disc -- II II Parking Brakes 61 II II Brake System 60, 96 I Brake Fluid 97 R FUEL MANAGEM[...]

82 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) 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 Steering [...]

83 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Pr emium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 79 and before sea sonal storage. When operating in heavy , wet snow conditions, lubr icate every 500 miles (800 km). Lack of lubrication will adversel[...]

84 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pump s. 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 [...]

85 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 79. 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[...]

86 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 of f all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. The sealing surfaces on the drain plug and the oil tan[...]

87 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 your Owner's Manual Supplement for the specific spa rk plug to be used in your machine. Change the spark plugs every 20[...]

88 MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation. The spark plug firing end condition sho uld be read after the engine has been warmed up and the vehicle has been driven at higher spe eds. Immediately check the spark plug for correct color . CAUTION! A hot exhaust system and engi ne can cause burns. Wear pr[...]

89 MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap . 2. Using the special wrench provided in the tool pouch, rota te the spark plug counterclockwise to remove. 3. Reverse the pr ocedure for spark plug installation. 4. T orque to 18-22 ft . lb s. (24-30 N m). 5. Reinstall the spark plug cap. Oil Lines Inspect oil line con[...]

90 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam filters periodically 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 carb u[...]

91 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water , which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper- ated at extremely low te mperatures , greater protectio n may be required. Please see your Pol[...]

92 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light CAUTION! S team and hot liquids will cause burns to your skin. Never remove the pressure cap when the engine is warm or hot. The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. If y[...]

93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contac[...]

94 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). Always allow the en gin e and exhaust system to co ol completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow a dequate time for the exhaust system to cool. Never perfo rm this procedure with the engine ru[...]

95 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[...]

96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 60. 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 ope[...]

97 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, meanin g 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 t[...]

98 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[...]

99 MAINTENANCE Lights 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 plenum covering from the headlight assembly . 2. Lift the rubber boot to exp[...]

100 MAINTENANCE Lights T aillight/Brakelight Replacement 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.[...]

101 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. W ARNING! If you become aware of higher th an normal clutch engagement or an unusual vibration or shift pattern, see your dealer immedia tely . Do not oper[...]

102 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 123. Al[...]

103 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 [...]

104 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. Rotate the driven clutch counte r- clockwise 1/4 turn by hand to ensure forward engagemen t before attempti ng to re[...]

105 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. T o ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the [...]

106 MAINTENANCE F all 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 oper ating condition. Matte Clear Coat Cleaning Matte finish products are prone to tr apping dirt, oils and other contami- nants. Polaris Indu stries rec[...]

107 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. Ro[...]

108 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 m[...]

109 MAINTENANCE T rack Maintenance T rack T ension 5. Check for specified slack between th e wear surface of the track clip and the plastic slider . Refer to the T rack T ension Data Chart on page 108. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or l oosen the track adjus ting screws to pro[...]

110 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 until the[...]

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

112 MAINTENANCE Steering 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 [...]

113 MAINTENANCE Steering System n Ski Skags W ARNING! W orn skis and/or skags will ad versely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressive carbide skags than the orig inal equipment, it may also be necess[...]

114 MAINTENANCE Steering 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[...]

115 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many componen ts. See page 1 18 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chass[...]

116 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 belt and store in a cool dry location. Do not lubricat e clutch components, except the driven clutch sh aft bus[...]

117 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 ransporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are insta[...]

118 POL ARIS PRODUCTS Part N o. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthet ic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.) 2877884 VES Gold Plus Synthetic 2-Cycle Engine Oil (2.5 gal.) 2877887 VES [...]

119 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 • SEE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEAL[...]

120 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 adjust (or repla[...]

121 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. • Make sure the fuel tank contains fuel. • I[...]

122 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static s ag (see page 46). • Change torsion spring to stif fer optional spring (see your dealer). • Revalve rear tr ack s hock (see your dealer). Rides too stiff in rear • Check for binding [...]

123 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low 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 off the ma chine in extremely cold weather and warm it up. Break machine loose fro[...]

124 W ARRANTY Service and W arranty Information Obtaining Service and W arranty Assistance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Cont act your Polaris dealer for replacement parts, service or warranty . Y o ur dealer receives freque nt updates on cha nges, modifications and tips on s[...]

125 WA RRANTY Service and W arranty Information Polaris Anti- Theft 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 pr oper law en forcement officia ls, the [...]

126 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 workmans hip. This warranty covers the parts and labor charges for repair or replacement of d efective parts that are cove red by this warranty .[...]

127 WA RRANTY 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 s[...]

128 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[...]

129 WA RRANTY 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 Polaris sno[...]

130 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[...]

131 WA RRANTY 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[...]

132 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 TO ANY PERSON FOR BREACH OF [...]

133 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 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[...]

134 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

135 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 55 Adjustabl e Headlights . . . . . . . . . . . 29 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Bearings . . . . . . . . . . . . . . . . . . . . . 116 Brake Components. . . . . . . . . . . . . . 96 Brake Fluid . . . . . . .[...]

137 INDEX G Gauge Cleaning. . . . . . . . . . . . . . . . . 40 H Handlebar Adjus tments. . . . . . . . . . . 54 Handlebar Angle . . . . . . . . . . . . . . . . 54 Handlebar Po sition . . . . . . . . . . . . . . 54 Headlight Adjus tment . . . . . . . . . . . . 29 Headlight Bulb Install ation . . . . . . . . 99 Headlight Bulb Removal . . . . . . . . [...]

138 INDEX S Ski Alignment . . . . . . . . . . . . . . . . 112 Ski Pressure . . . . . . . . . . . . . . . . . . . 49 Ski Skags . . . . . . . . . . . . . . . . . . . . 113 Slide Rail and Track Cooling . . . . . 67 Snow Conditions . . . . . . . . . . . . . . . 20 Spark Plug Conditi on . . . . . . . . . . . . 88 Spark Plug Removal . . . . . . . . . . .[...]