Polaris Xer manual

[...]

[...]

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

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

2 WELCOME Dear Par ents: W e believe your children shou ld have the opportunity to enjoy The W ay Out experience along with you. W e've provided this ow ner's manual to assist you and your children in learning abou t the safe operation and care of your new Po laris snowmobile. Please review the information in this manual with any ch ild w[...]

3 WELCOME Dear Childr en: Before you ride your new Polaris sn owmobile, there are some important things that you need to know . Y our parents and Po laris want yo u to enjoy riding your new snowmobile, an d that's why you n eed to read and understand the information in yo ur owner's manual. Ask your parents to exp lain anything you d on&a[...]

4 POLARIS and POLARIS THE W A Y OU T are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production compo nents, some minor discre[...]

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 mu st complete the registration form included with your snowmobile and forward it to us . This completed form is ne cessary to[...]

7 INTRODUCTION Preservation of the Environment T eac h your child to drive their snow mobile with consideration for the protection and preservatio n of the en vironment. 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 co ntinuing enviro nme ntal education campaign, we are encouraging state and provincial go vernments acros s the snowbelt to adopt rigorous safety training programs which also encourage protec- tion of our enviro nment, wildlife and vegetation . Snowmobile clubs [...]

9 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 duplicat ed only by mating a Polaris key blank with o ne of your existing keys, so if both keys are lost, the ignition switch must be replac e[...]

10 SAFETY The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The sa fety alert symb ol , on your vehicle or in this manual, alerts you to the potential for in jury . W ARNING The[...]

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 yo u in its safe operation. For the safety of the operator , always make sure that the snowmobile is in excellent operating condition at all ti mes. W e strongly recommend that the operator , as well as an adu lt, chec k major and vital [...]

13 SAFETY Safety Decals Safety an d warning deca ls have bee n placed on the vehicl e for the oper- ator's protection. Make sure the operato r understands the inf ormation on all decals. If any decal becomes illegi ble or comes of f, contact your Polaris dealer for a replace ment. Replacement safety de cals 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 en gine is running, push this button down to stop the eng ine. Pull the stop switch up before 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 off to put gas in your snowm obile. Never take the gas cap of f. Always make sure it's tightly closed. Brake Lever Squeeze the brake lever toward the hand lebar to make yo ur snowmobile slow do wn or s top. Ignition Switch The ignition switch key must be turn ed ON [...]

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

17 Y OUTH SECTION Know Y our Snowmobile Hood The hood covers the moving and hot parts of the en gine. Always make sure the hood is securely latched before you ride. Headlight The headlight is always on wh en the engine is running . It helps others see you when yo u're riding during day light, but it's not meant to be strong enou gh to hel[...]

18 Y OUTH SECTION Know Y our Snowmobile Let's revie w the 3 ways to sto p your snowmobile: 1. Push the stop switch down. 2. Pull the tether strap off the switch. 3. T urn the ke y off. ST OP Ignition Key & Switch Stop Switch Te t h e r Strap/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 s ure the snowmobi le is safe to ride. Every time you want to ride yo ur snowmobile, always h ave an adult help you check these things before you start the engine. n Throttle Lever Squeeze the throttle l[...]

20 Y OUTH SECTION Pre-Ride Check n Gas Leve l Have an adult check the gas leve l to see if your snowmobile needs more gas. Children should ne ver open the gas cap or add gas. Always have an adult do this. Before anyone adds gas to yo ur 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 P olaris snowmobile. This snowmobile is not a toy . There are so me things you can do and there are some things you mu st never do. Rules are very i mportant when you' re driving a snowmobile. Adults have ridi ng rules, too. The rules help keep us safe when we ri[...]

22 Y OUTH SECTION Riding Rules " Always wear the right kind of clothing wh en you ride your snowmo- bile. Always wear a helmet with a face shield or goggles. W ear a warm jacket and snowpants. Make sure your clothing fits pro perly . T ight clothing cou ld keep you fro m moving easi ly . Baggy clothing could hang do wn and get caught in the tr[...]

23 Y OUTH SECTION Riding Rules " Always sit down when yo u drive. Kee p both hands o n the hand lebars. Keep both feet on the runn ing boards. " Never follow another snowmobile too closely . Always allow lots of space to stop your snowmobile. " Ride your snowmo bile only where you k now it's safe to drive and where you have perm[...]

24 Y OUTH SECTION Riding Rules Learn how to use your hands and arms as signals. Use these signals to let others know when yo u are getting ready to turn or stop yo ur snow- mobile. Read and un derstand your 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 mind. Ne ver 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 befo re allowing anyo ne to op erate this snowmobile. It's also a good idea to review it periodical ly to reinforce the inform ation. It's very important to familiarize all opera[...]

27 ADUL T SECTION Pre-Ride Check n Check the throt tle safety 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 lev er pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration. Apply a slight amount of throttle opening. A prop[...]

28 ADUL T SECTION Pre-Ride Check n Inspec t the tr ack 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 w[...]

29 ADUL T SECTION Operation W arnings n Do not carry passen gers This snowmobile is designed for a single operator . n Do not operate with in take s ilencer remove d n Stay clear of trac k n Do not operate with driv e chain guard removed CA UTION If the engine is operated with the intake silencer removed, damage to the engine may occur . Do not ope[...]

30 ADUL T SECTION Operation W arnings n Do not touch the engine after it's been running n Disabled operat ors WA R N I N G Hot components can cause serious burns to skin. Do not touch en gine and exhaust parts after the engine has be en running. WA R N I N G Safe operation of this rider-active vehicle requires good ju dgement and physi- cal sk[...]

31 ADUL T SECTION Operation W arnings n Check b rake leve r travel Depress the brake lever fully . Mea- sure the clearance between the lever and brake bloc k. Clearance 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 infor- mation on page 5 6. n Secure [...]

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

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

34 ADUL T SECTION Operation W arnings n Stop engine before a ttempting 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 followed. They have been e stablished for the pro tection of all sno wmobile riders. Many local orga[...]

35 ADUL T SECTION Operation W arnings n Instruct a ll operators T eac h all young drivers to always be alert and to pay attention to the driving area ahead. When teaching inexperience d operators to ride, set up a predetermined cou rse. Establish boundaries and make sure all oper- ators know and understand th em. Make sure they know how to driv e a[...]

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 mind. Ne ver 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 child may no t be capable of maneuvering bo dy weight as needed for op erating on hills. If traveling on hills is unavoidable, teach your child to use extreme caution and obey the following proper operating pro cedures. Driving Uphill Driving uphill sh[...]

39 ADUL T SECTION Operation W arnings Windchill/T emperature Charts The following information is provided to help you determine when tem- peratures be come da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Readi ng ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T[...]

40 ADUL T SECTION Component Identification Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshiel d Flag Tr a c k T aillight Rear Suspension Nosepan T railing Arm Fr o n t Bumper Rear Bumper[...]

41 ADUL T SECTION Component Identification F uel Cap Recoil Starter Handle Ignition K ey & Switch Brake Lever Throttle Lever Engine St op Switch Te t h e r Strap/Switch Choke Knob Hood Hold-Down Strap[...]

42 ADUL T SECTION Break-In P eriod Engine Break-In The break-in perio d for your new snow mobile is defined as the first ten hours of operation, or the time it take s to use the first two tanks full 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 efficie[...]

43 ADUL T SECTION Operation Fu e l When refueling, use eith er lead ed or unleaded gasoline with a min imum pump octa ne number of 87=(R+ M)/2 octane. Do not use E-85 fu el. WA R N I N G Gasoline is highly flammable and expl osive under certain cond itions. • Always exercise extreme caution whenever handling gasolin e. • Always refuel with the [...]

44 ADUL T SECTION Operation Speed/P erformance 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 mind. Ne ver allow the child to operate this vehi- cle without adult supervision. Y ou can regulate the speed and accelerat[...]

45 ADUL T SECTION Operation Starting the Engine Never start the engine before performing the Pre- Ride Check. See pages 19 and 25. 1. T urn the ke y to ON. 2. Pull the engine stop switc h up to the RUN position. 3. Do not use the choke when startin g a warm engine. If the engine is cold, pull the choke lever completely out to the FULL ON position. [...]

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 W arm-Up Always warm up the engine, drive tr ain and track before operating the snowmobile. Support the r ear with an appropriate track stand. The track should be sus pended appr oximately 4 I (10 cm) off the ground. 1. S tart the engine. Allow it to idle for two to three minutes. 2. Engage the driv e system abr[...]

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 P olaris Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 94. The recommen ded maintena nce schedu l e fo[...]

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

51 ADUL T SECTION Maintenance P eriodic Maintenance Chart ITEM SEE PA G E DAIL Y WE EKL Y O R BEFORE EXTENDED PERIOD O F 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 a nd spindle bolts if loose -- X[...]

52 ADUL T SECTION Maintenance Spark Plugs A new engine can cause temporary spar k plu g fouling due to the preser- vative added durin g the assembly process. A void prolonged idle speeds, which cause p lug fouling and carbon ization. Refer to the specifications section beginning on page 80 for reco m- mended spark p lug type and gap. Spark plug con[...]

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 shou ld not be white. A whi te insulator tip indicates overhea tin[...]

54 ADUL T SECTION Maintenance F uel V a lve/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 fu el compou nds can occur . Replace any worn or damaged components. Exhaust System At approximately 50 hours, check th [...]

55 ADUL T SECTION Maintenance Carburetor Proper carburetor adjustment is cri tical, since a mixt ure too lean (too much air , too little fuel) will resul t in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failure . A lean mixtu re can be th e result of fue[...]

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

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 secu rely . T ighten hardware as required. 5. T ighten the adju ster jam nut and slide the rubber protectors onto the a[...]

58 ADUL T SECTION Maintenance Throttle Cable Lubrication W ith the engine of f, lubricate the throttle cable occasionally . T u rn 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 [...]

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 nu t on the chai n tensioner . 2. Raise the tensioner until the co rrect deflecti on is attained. 3. T ighten the nut to 15-18 ft. lbs. (20-24 Nm). NOTE: When the chain has stretched to [...]

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 Pola ris Premium 4 All Season Synthetic Oil or any class SE, SF (API classifi cation) or higher grade oil. If multi- grade oil is used, oil consumption will increase when the ambient tem- perature is high. Always check and change the oil at the intervals outl[...]

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 located under the bulkhea d and in front of the engi ne. 3. Remove the drain plug. 4. Remove th e dipstick and wipe it dry with [...]

63 ADUL T SECTION Maintenance T rack T e nsion 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 of f the ground with an appropriate snow- mobile support. 4. Hang a 10-po und (4.5 k[...]

64 ADUL T SECTION Maintenance T rack T ensio n 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 sid es of the track. 3. Repeat the measurement on the other side of the track. NOTE: Check tension more fre quently when the ma chine is new . 4. S tart the engine and[...]

65 ADUL T SECTION Maintenance T rack Alignment Check track alignment at the interval s outlined in the periodic mainte- nance chart begin ning on page 50. M ake 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 of f the[...]

66 ADUL T SECTION Maintenance T rack W arm Up After storing your sno wmobile outside overnigh t, warm up the track before driving the snow- mobile. This reduces drive clutch wear . 1. Support the rear of the snowmobile slightly of f the ground wi th an appropriate snowmobile supp ort. 2. S tart the engine. 3. Abruptly engage the clutch, allowi ng t[...]

67 ADUL T SECTION Maintenance T rack Inspection Check track condition at the intervals outlined in the periodic mainte- nance cha rt beginning on pag e 50. 1. Support the rear of the snowmobile slightly of f the ground with an appropriate snowmobile supp ort. 2. Rotate the trac k by hand to check for wear or damage. 3. Carefully examine the track a[...]

68 ADUL T SECTION Maintenance Slider Replacement Polaris rail slides have a wear limit indicator groove to in dicate 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. F ail- ure to do so may result in perma- nent damage to the track or rails. T rack Lubricat[...]

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 st raight ahead position, an d with vehicle weight compressing the suspension, measure[...]

70 ADUL T SECTION Maintenance Handlebar Adjustment 1. Slide th e handlebar pad upward to access the adjuster bolts. If additional room is required, u nzip one of the handlebar pad zipp ers and roll the pad to the side. 2. Remove the upper 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 ba r 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 w[...]

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

73 ADUL T SECTION Maintenance Lubrication Recommendations Inspect and lubricate all greaseable co mponents at the intervals outlined in the Periodic Maintenance Chart beg inning on page 50. Controls and Linkage Lubricate all bushings, spindle shafts, and tie rod ends with a ligh t coat of oil or grease. Lubricate throttle and brake controls and cab[...]

74 ADUL T SECTION Maintenance W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. 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 comp onents. F og 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 engi ne is level or t[...]

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 eng ine parts during storage. See page 8 2 for the part numbers of Polaris products. 1. Fill the fuel tank with fresh fuel. 2. Add Polaris Carbon Clean Fuel T [...]

77 ADUL T SECTION Maintenance Storage T rack and Suspension Support the rear of the snowmobile 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 under it to remove tension from the shocks and springs. This will minimize fatigue on[...]

78 ADUL T SECTION Maintenance T ransporting the Snowmobile Whenever the snowmobile is transp orted the following measures should be taken: 1. T urn the fuel valve off. 2. Be sure the fuel cap is installed correc tly . 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. Po ssible 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 Se[...]

80 SPECIFICA TIONS Capacities and Dimensions Body Style Mini Indy Rider/Weight Capacity 1/150 lbs. (6 8 kg) maximum Dry W eight 147.5 lbs. (67 kg) F uel T ank Capacity .5 gal. (1.9 l) Engine Oi l 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 Widt h 10 in. (25.[...]

81 SPECIFICA TIONS Carburetor Jet ting AMBIENT TEMPERA TURE AL TITUDE Meters (F e et) Below -25 ° F (-31 ° C) -30 ° to -1 0 ° 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) Abo[...]

82 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubri cants 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Pre mium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase/T ransmission Lubricants 2873602 Pre mium Synthetic Gearcase Lubricant (qt.) 2871653 Pre mium F ront Gearcase Fluid (8 oz.) 2871654 Pre mium Demand Drive Hub Fluid (8 oz.) Grease[...]

83 W ARRANTY Service and W arranty Information Obtaining Service and W arranty Assistance Read and understand the service data an d the Po laris warranty in formation 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 [...]

84 W A RRANTY Service and W arranty Information P olaris Anti- Theft System The Polaris anti-theft system (P A TS) monitori ng program is designed to aid owners of registered snowm obiles in recovery of stolen machines. Administration 1. Polari s snowmobile o wner reports theft. A . In additio n to notifying th e pr oper law enforcement offici als,[...]

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

86 W A RRANTY Limitations of wa rranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES 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[...]

87 W ARRANTY Conditions and Ex clusions 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 service bulle tins and have the consumer sign the PDI form prior to delivery may [...]

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

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

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

91 W ARRANTY Exported V ehicles How to Get Service In the Country whe re your 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 arranty or Service Bulletin repairs may be requested from any authorized Polari[...]

92 W A RRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine emi ssions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries In c. warrants that at the time it is first purchas ed, this emissi ons-cer tified snowmobile engine meets current U.S. Environmental Protection[...]

93 W ARRANTY Snowmobile Engine Emis sions Limited W arranty Some states do not allow lim itations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law . This limited warranty excludes failures not ca used by a defect in material or workmanship. This lim- ited warranty does[...]

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 with an accurate log of maintenance and servi ces performed on the snowmobile. DA TE HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 50 100 150[...]

95 MAINTENANCE L OG DA TE HOURS TECHNICI AN SERVICE PERFORMED / COMMENTS[...]

96 INDEX A Air Pollut ion . . . . . . . . . . . . . . . . . . . 7 B Bearings . . . . . . . . . . . . . . . . . . . . . . 73 Brake Cable Adjustment . . . . . . . 56-57 Brake Lever . . . . . . . . . . . . . . . . . . . 15 Brake Lever Tr avel . . . . . . . . . . . . . 56 Break-In Period . . . . . . . . . . . . . . . . 42 C Carburetor . . . . . . . . .[...]

97 INDEX S Safety Dec als . . . . . . . . . . . . . . . . . . 13 Safety Sy mbols . . . . . . . . . . . . . . . . . 10 Signal Wo rds . . . . . . . . . . . . . . . . . . . 10 Skag Repla cement. . . . . . . . . . . . . . . 71 Ski Skags . . . . . . . . . . . . . . . . . . . . . . 71 Slider Rep lacement . . . . . . . . . . . . . . 68 Snow and Ice Build-[...]