Polaris 440 IQ инструкция обслуживания

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W ARNING Read, understand, and follow al l of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious inj ury or death. The engine exhaust from this product contains chemical s known to the S tate of Californi a to cause cancer , birth defects or other reprod[...]

1 WELC OME Thank you for purcha sing a Polar is vehicle , and welcome to our world-w ide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cr eationa l products. S Snowmobiles S All-te rr ain vehic les ( A TVs) S RANGER utility vehicle s S V ict or y mo to rcycl es W e belie ve Polaris sets a standa rd of exc ellen[...]

2 PO L AR IS an d PO L AR IS T HE W A Y OUT are registered trad emark s of Po laris Indus t ri e s Inc . Copyri ght 2006 Pola r is Sa le s I nc. Al l i nf orm at ion c ont ai ne d wi thi n thi s publi c at i on is bas e d on t he l at e st pr oduc t inf orm at i on at t he t ime of publ ic a t ion. Due to cons t ant imp ro vem ents in the desig n a[...]

3 TABLE OF CONTENTS Introducti on 4 ............................... This section contains helpf ul informa tion for owne rs and dr ivers a nd illustrate s the loca tion of impor tant identif ication numbe rs tha t should be rec orde d in the owner ’ s manual. Safety 7 ..................................... This sec tion desc ribes sa fe ve hicle o[...]

4 INTRODUCTION Impor tant N otes for Ow ners and D ri vers After r eading this manual, store it in the snowmobile for conve nient ref ere nce . It should remain with the snowmobile when sold. Some of the illustrations and photos used in this manua l are gene ra l repr esen tations. Y our model may dif fe r . Follow the maintena nce progr am ou tlin[...]

5 INTRODUCTION Pr eser vation of the Envir onm ent Polaris is committe d to supporting a n environme ntal educ ation campa ign. W e encour age state a nd provincia l governments ac ross the snowbelt to adopt rigor ous safety tr aining progr ams that enc ourage protec tion of our e nvironmen t, including wildlife and ve geta tion. Snowmobile clubs a[...]

6 INTRODUCTION V ehi cle Identifi cation Num ber s Record your snowmobi le’ s id entifi catio n numbers in t he spaces provided. V ehicle Model Number : Tunnel VIN: (lower right s ide of the tunnel) Engine Ser ial Number: (right fr ont s ide of engine crank c as e)[...]

7 SAFE TY Operator S afety The following signa l words and symbols a ppear throughout this manual a nd on your vehic le. Y our sa fety is involve d when these words and symbols are use d. Become f amilia r with their mea nings before rea ding the manual. The safety aler t sy mbol , on your vehicle or in this manual, alert s you to t he pot ential f[...]

8 SAFE TY Operator S afety Follow the re comme nded mainte nance progra m outlined beginning on page 59 of this manua l to ensur e that a ll critic al c omponents on the snowmobile ar e thoroughly inspec ted by your de aler a t specific mi leag e in terv als . W ARNING Driving a s nowmobile requir es your full at t ention. DO NO T dr ink alcohol or[...]

9 SAFE TY Operator S afety Stay Clear of T r ack Y our snowmobile is propelle d by a re volving trac k that must be partia lly expose d for pr oper ope ration. W ARNING Serious injuries may res ult if hands, f eet, or clot hing become ent angled in the t rac k. Be alert when riding, and rem ain properly seat ed to st ay c lear of t he tr ack. Never[...]

10 SAFE TY Operator S afety Survival P repar ation For your safety , always ride in a group of other snowmobilers. Alwa ys tell someone where you’re going a nd how long you expe ct to be gone . If it isn’ t possible to r ide with othe rs, and you must tra vel into re mote areas, al ways carry s urvi val eq ui pm ent t hat ’ s app ropri at e t[...]

11 SAFE TY Operator S afety Dis a bl e d Op e rat o rs Safe ope ration of this rider - active ve hicle r equire s good judgement and physica l skills. Opera tors with c ognitive or physical disa bilities ha ve an incr ea sed risk of loss of control, which c ould result in se rious injury or death. Rider Capacity Y our Polaris snowmobile is designed[...]

12 SAFE TY Operator S afety Driver A wareness Slow down when trave ling near poles, pos ts , or o th er obs tacl es . B e esp ecial l y aler t if you’re snowmobiling after da rk. Always be on the alert for wir e fenc es. Single strands are e specia lly dangerous, si nce th ere may be a g reat di st ance betwe en posts. Guy w ires on utility pole [...]

13 SAFE TY Operator S afety A valan ches Snowmobilers should alwa ys be pr operly traine d and equippe d befor e tra veling in mountainous ter rain: S T ake an aval anch e clas s S T ravel wit h exp erien ced peop le S T ravel on designa ted tra ils S Make su re each person i s equ ip ped wi th a shovel, probe and a valanche beacon. Y ou don’ t h[...]

14 SAFE TY Operator S afety Ice and S now Buil d - up W ARNING Ice and s now build-up m ay int erfer e with t he st eering of y our machine, res ulting in s erious injur y or deat h. K eep the underhood area f ree of snow and ic e. Befo re driving, ma nually turn the skis to the left a nd right to be sur e ice a nd snow ar e not inter fer ing with [...]

15 SAFE TY Operator S afety Driving in Hilly T errain W ARNING Climbing a hill or c ross ing the f ace of a slope m ay res ult in los s of balance and mac hine roll-ov er , caus ing serious injury or death. Use caut ion and good judgement when driv ing in hilly t errain. Use e xtra c aution w hen ope rating in hilly te rr ain. If c limbing a hill i[...]

16 SAFE TY Operator S afety Drive Belt Do not ope r ate t he eng ine wit h the drive be lt r emov ed. Any servic ing that r equire s opera tion without a belt must be pe rforme d by your dea ler . Oper ation of the e ngine with the be lt removed ma y result in injur y or dama ge to the e ngine. Intake Silencer Do not oper at e the engine w ith the [...]

17 SAFE TY Operator S afety Inadequate S now Condi tions W ARNING Do not dr ive for prolonged per iods on black top, grav el, or ice. Doing so could c ause irr evers ible tr ack dam age and lead to serious injur y . Since snow provides the only lubrication for the power slide suspension and, on liquid coole d models, cooling for the engine, adequa [...]

18 SAFE TY Operator S afety Dr ivi ng Respons ibly Every snowmobile handles dif feren tly , and even the most docile conditions may become danger ous if oper ators dr ive imprope rly . If you’re ne w to snowmobiling, acqua int yourself with the machine and with wha t it will an d won’ t do unde r va rious conditions. Eve n seasone d driver s sh[...]

19 SAFE TY Operator S afety Windchill/T emperatur e Charts The following inf ormation is provide d to help you dete rmine w hen temper ature s beco me dange rous for riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Act ual Ther momet er Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2 0 -25 -30 -35 -40 -4 5 Equivalent T emperatur e ( ° F) [...]

20 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he snowmobil e for your prot ect io n. R ead and fo ll ow t he in st ruct io ns o f the decal s on t he sno wmo bi le careful l y . If any of th e decals d epi cted i n t his m anual differ from the decals o n your snowmobil e, always read and follow the ins tru cti on s[...]

21 SAFE TY Safety D ecals and Locations T rack W arning The track warning d ecal is l o cat ed on th e rear of the tunnel: Passenger W arning This snowmobile is designed for one opera tor only . A “No Passenger ” warnin g decal i s l ocat ed on t he low er cons ol e: + +[...]

22 SAFE TY Safety D ecals and Locations Operation W arning +[...]

23 SAFE TY Safety D ecals and Locations Operation W arning[...]

24 FEATURES AND CONTROLS 1. Brak e Lever 2. T ach om eter 3. T empera ture Light 4. Engine Stop Switch 5. T hrottle Contr ol 6. Choke Control 7. Reco il S tart er Hand le 8. Fue l Filler Cap 9. Par k Brake Lock 10. Hea dlight Dimmer Switch 1 1. Handl ebar Gri p W armer/ Thumbwarme r Switch 12. T ethe r Switch 13. Master Cylinder 14. Dragon t Igniti[...]

25 FEATURES AND CONTROLS 1. Handlebar 2. Winds hield 3. Headlight 4. Hood 5. Nosepan 6. Skis 7. T rack 8. Suspension 9. S now Flap 10. T aillights 1 1. Seat 9 4 11 10 7 8 5 6 1 2 3[...]

26 FEATURES AND CONTROLS Polaris DRAGON Ignition System Y our snowmobile is equippe d with an ignition syste m fea ture that improves c ompetition pe rfor mance by incre asing e xhaust system temper ature. The DRAGON Ign ition System provide s maximum “hol esh ot ” perform ance fo r racin g app li cat ion s. W ARNING DRAGO N mode incr eases t h[...]

27 FEATURES AND CONTROLS Polaris DRAGON Ignition System DRAGON Mode Op eration 1. W arm up the engine and trac k. See page 52. 2. When s tag ed at th e st arti ng line, depre ss and hold the DRAGON (horn) butt on on the l eft hand leb ar (1). 3. Slowly advance the thr ottle to the wide -open position while kee ping the button depre ssed. 4. Release[...]

1 3 2 4 28 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Independe nt Front S uspensi on (IFS ) Brea k in the suspension f or about 150 mile s (240 km) be fore making any f ine-tuning a djustments. Settings will vary f rom rider to rider , depending on rider weight, vehicle spe ed, riding style, and trail conditions. W e rec ommend st arti ng[...]

29 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents W ARNING Always verif y s ki alignment bef ore mak ing adjust ment s t o the IF S. See page 92 to c heck alignm ent. If t he sk is are m isaligned, see your dealer , as t he cam ber adjust ment may also be affec ted. The tension a t which the shoc k coil spring is set is ca lled spring preload.[...]

1 30 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Front S hock S pri ng Pr eloa d Increasi ng s pri ng prel oad wi ll i ncrease ski-to-gr ound pressur e. Dec rea sing spring preloa d will decrea se ski-to-ground pressur e. Whe n adjusting, be sure the springs on both the lef t and right sides of the mach ine are a t the same adjustment. A=L [...]

31 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Shoc k V alving W alker /Evans shocks c an be r evalve d if spring pre load alone isn’ t suf fic ient and f urther adjustment is de sired to c ontrol suspension stif fne ss. W ARNING Changing shock valv ing on W alker/Ev ans shock s requires s pecial tools and a s ound knowledge of mec hanica[...]

32 THE PE RFECT FIT Rear S uspension Adjustments Rider we ight, riding style, trail conditions, and ve hicle spe ed a ll af fec t suspension a ction. Each rear sus pen si on can be adj us ted t o su it ri der preferen ce and deliver e xce llent perf ormanc e for a given se t of conditions. However , all suspension designs and adjustments involve a [...]

33 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Rear T o rsion Spring T ension T o adjust re ar tor sion spring ten sion, rotate the three -position ca m using the engine spark plug tool. Dif ferent ra te torsion spr ings are ava ilable if a firme r ride is desire d. Contact your deale r for more info rmat io n. The following inf ormation is p[...]

34 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Suspension Cou pling On all P olaris snowmobile re ar suspensions, there ar e two torque arms that contr ol the move ment of the rail be am. Prior to the advent of suspension coupling, these torque ar ms could move independently of each other . Rear susp ension coupl in g links t he movement of t[...]

35 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Rear Rear S cissor Stop ( RRS S) The rea r rea r scissor stop (RRSS) couples the movement of the rear torque ar m with the front torque arm and limits the amount of independe nt movement betwee n the rear torque a nd the front torque arm. Adjusting the RRSS either allow s mo re weight to tran sfe[...]

36 THE PE RFECT FIT IQ Rear S uspension Adjustm ents W eight T ransfer During Acceleration IQ Rear Rear Scisso r Sto p (R RSS) The pr efe rre d method for c ontrolling we ight tran sfer du rin g accel erati on of t he IQ rear suspension is by adjusting the RRSS . Use the scissor stop tool (1) locate d in your tool kit to make the a djustments. T o [...]

37 THE PE RFECT FIT Handlebar Adjustm ents Handlebar with Riser Block 1. Remove the handlebar cover to expose the handleba r mounting hardwa re. 2. Using a 1/4” Allen wrench, loosen the tw o bolts on the bottom of the riser or the two bolts on the t op of the riser , depending on the type of adjustme nt requir ed. 3. Adjust the handlebar to the d[...]

38 THE PE RFECT FIT Accessor ies Pol aris o ff ers a wi de range of accesso ries for your snowmobi le to hel p make each ri de more enj oyable. See your dealer for a com plet e lis t o f accesso ries . Use only Pol aris part s and accesso ries on your Pol aris snowmobi le. Use of unap prov ed part s and acces sori es m ay resul t i n: S Non-c ompli[...]

39 THE PE RFECT FIT Accessor ies T rac tion Pr oducts Another w ay to tailor your mac hine is to install tra ction pr oducts. See your deale r about installing studs and/or ca rbides. Ma ny tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice an d as si st ance. NOT E: Bef ore equipping y our mac hine with t [...]

40 THE PE RFECT FIT Accessor ies CAUTION Aggres sive s tudding pat ter ns may requir e grinding prot ruding stud bolt s f lush t o prev ent idler wheel damage. Maint ain tr ack tens ion on studded t rac ks on t he t ight s ide of t he spec to pr event heat exchanger damage. Cent er of st ud must be at least 1 1/8 ″ (2. 86 cm) fr om out side edge [...]

41 THE PE RFECT FIT Accessor ies W ear Str ips Polaris IQ models are manufa cture d with tunnel we ar str ips or wear strip coole rs installe d. T o avoid exce ssive tunne l wear , tunnel wea r strips must be installe d whene ver tr ack studding is use d. W ear str ips are designed for a spe cific stud length. See your dealer’ s studding chart fo[...]

42 PRE -RIDE IN SPECTI ON S Pre - Ride Ch ecklis t Inspec t all ite ms on the c heck list for pr oper ope ra tion or c ondition before each use o f th e sn owm obi le. P rocedu res are o u tlined on the referenced pages . Look for a checkm ark ( n ) on the ref erenc ed page s to locate the pre -ride inspe ction items. I t e m S e e P a g e Item S e[...]

43 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine W ARNING Worn, damaged, or malf unct ioning component s may c ause serious injury or death. Bef ore s tar ting t he engine, check all component s t o be sur e of pr oper operat ion. Read a nd Under stand Y our Owne r ’ s Manual Read t he Owner ’ s M anual co mp let ely an d refer to it o[...]

44 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Hydraulic Br akes Always ch eck th e following ite ms to assur e proper ope ration bef ore starting the engine . Brake L ever T ravel Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1.3 cm) . A smalle r distanc e indicate s low brake fluid level or ai[...]

45 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Par k Brake Lever L ock Y our snowmobile may have a park bra ke lever loc k located over the brake le ver . Use the bra ke lever lock only when you want the machine to rem ain s tat io nary; for exam pl e, wh en parked o n an in cli ne for a perio d o f fiv e mi nut es o r l ess. T o app l[...]

46 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Check for Proper Operation of Steering System Manually tur n the skis comple tely to the right a nd to the left. If any dif fic ulty is encounte red, c heck f or ice and snow build- up that may be obstructing the stee ring linkage . Make sure all gre asab le components are prop erly l ub r[...]

47 PRE -RIDE IN SPECTI ON S Star t the E ngine and Check n Engine St op Switc h: Che ck the auxiliar y shut-of f switch for proper opera tion. Push down t o stop the engine . Pull up to relea se and a llow starting o f the engine . n T ether S wi tch: Make sure the engine shuts of f when the tether is remove d from the switch. n Lightin g: Check th[...]

48 OPERATION Engine B r eak -In No single action on your part is as import ant to long, trouble-free mac hine life as prope r bre ak-in of a new or r ebuilt engine. P remix the first 3.5 gallons (13.2 l) of g asoline with 16 oz . (473 ml) of the rec ommende d 2-cyc le rac ing oil (28:1). P remix futur e gasoline at 32:1. CAUTION Exc essiv e heat bu[...]

49 OPERATION Oil Recom m endations The only source of engine lubr ication for your engine c omes from lubrica tion adde d to the fuel. W e highly recomme nd the use of only Polaris produc ts. W e’r e continuously te sting lubric ants and pr ovide the highest perf ormanc e products ava ilable for your snowmobile ’ s engine. W e rec ommend the us[...]

50 OPERATION Fuel W ARNING Gasoline is highly f lamm able and explosiv e under cer tain conditi ons. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always ref uel with t he engine st opped, and outdoor s or in a well ventilat ed area. S Do not over fill t he t ank. Do not f ill the t ank nec k. S Do not sm oke or allow open fl[...]

51 OPERATION Star ting the E ngine W ARNING Befor e st art ing the engine, always ref er t o all saf ety warnings pertaining t o snowm obile operat ion. Nev er st art your snowmobile without chec king all com ponents to be s ure of proper oper ation. See Check Bef ore St art ing t he Engine beginning on page 43. Sta rti ng a Cold E ngine Do not dep[...]

52 OPERATION Slide Rail and T rack Cooling CAUTION Inadequat e cooling and lubric ation will lead t o over heating of t he slide rail and t rac k, r esult ing in premat ure wear and f ailure. Reduce speeds and fr equently drive int o f resh s now to allow adequate cooling and polis hing of t he slide r ail and tr ack surf aces. Avoid operat ing on [...]

53 OPERATION Engine and T r ack Warm -Up 2. S tart the e ngine and a llow it to warm up two to thr ee minute s. 3. Depre ss the throttle abruptly a nd allow the trac k to rotate seve ra l revolutions. NOT E: I t will t ake longer to war m up t he tr ack s ufficient ly dur ing colder out door temper atur es. 4. Release the throttle , apply the brake[...]

54 OPERATION Car bur etion Pro per carbur eto r adju st ment i s crit i cal. A lean m i xtu re (too m uch ai r , too little fue l) may r esult in piston burning, bea ring fa ilure , or comple te engine fa ilure . A rich mixture (too much fue l, too little air) may foul plugs an d cause gener ally poor e ngine per forma nce. A lean mixture ma y be c[...]

55 OPERATION Car bur etion Jetting Guidelin es Change s in altitude a nd temper ature af fect air d ensity , which is the amount of oxygen availa ble for c ombustion. In low elevations a nd cold tempe rature s, the air has more oxygen. In higher ele vations and higher te mpera tures, the air is le ss dense. Carbur etors on most Polar is models ar e[...]

56 OPERATION n Engine S top Sw itch Push down on the engine stop switch (1) to stop the engine in an emer gency . T o restart the engine, pull the switch up to the ON position. Em er gency Stoppi ng The following cha rt lists methods for stopping the snowmobile in the eve nt of an eme r genc y . Refer to page 56 f or more inf ormation a bout the en[...]

57 OPERATION Em ergency S tar ting Y our machine is e quipped with a tool kit containing esse ntial tools for emergency us e. If the recoi l st art er syst em fai l s, an em ergency st art strap is pr ovided in the kit. W ARNING Serious injury c an result f rom wr apping the s tar t s tr ap around your hand while us ing the em ergency st art ing pr[...]

58 OPERATION Daily Storage At th e end of each ride, p ark the sno wmo bi le o n a l evel su rface and support it at the rear with an a ppropria te trac k stand. The tra ck should be suspended a pproxima tely 4 ″ ( 10 cm) of f the ground. Cover the mac hine with an appropr iate cove r . T owing W ARNING Object s t owed wit h a rope have no br aki[...]

59 MAINTENANCE Polar is Recom m ended Maintenance Pr ogr am T o ensure many trouble-free miles of snowmobiling enjoyme nt, follow rec ommende d re gular ma intenanc e a nd servic e c heck s outlined in this manu al. R ecord s ervi ces perform ed in t he Mai nt enan ce Record at t he rea r of this manual. The rec ommende d maintenanc e sche dule on [...]

60 MAINTENANCE Per iodic Maintenance Inter val T able The following char t is a guide based on ave rage r iding conditions. Y ou may ne ed to incr ease fre quency ba sed on r iding conditions. When ins pect i on rev eals t he need for rep lacem ent part s, al ways us e gen ui ne Polaris pa rts, ava ilable f rom your Pola ris de aler . See P Frequen[...]

61 MAINTENANCE Per iodic Maintenance Inter val T able See P Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season Brakes Hose Rou tin g -- I I I I Hos e Condition -- I I I I Fluid Leak s -- I I I I Brak e Pads 77 I I I I Brake Disc -- I I I I Parking Brakes 45 I I I I Brak e Sy s tem 43, 77 I Br[...]

62 MAINTENANCE Per iodic Maintenance Inter val T able See P Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season Chassis Sk i T oe A lignment -- I I I Sus pension Mounting Bolts -- I I I I I Steering F astener s -- I I I I C Rear Sus pens ion Fas teners -- I I I I I Sus pension S hoc k O il -- [...]

63 MAINTENANCE Lubri cation Lack of lubrica tion will adve rsely a f fec t your ride a nd the life of compone nts. Lubricate with Polaris Pre mium All Sea son Grea se a t 500 miles (800 km) initially , ever y 1000 miles (1600 km) afte r that, and before o ff-season s to rage each year . A greas e gun ki t, co mp let e wit h grea se and ada ptors, i[...]

64 MAINTENANCE Lubri cation Front S uspens ion T wo compone nts of the IQ front suspension a nd stee ring requir e lubrica tion. S Grea se the left and right spindles. Raise the front end of the ma- chine to per mit better gre ase e ntry into the spindle are a. S Lubrica te the steer ing post U-joint.[...]

65 MAINTENANCE Lubri cation Throttl e Cable Lubric ate the throttle c able ( 1) lightly with grea se or oil. W ith the engine of f, turn th e hand leb ars t o t he l eft an d lubrica te libera lly as shown. Choke a nd Cable Lubrica te the choke slide (2) and c ables lightly with oil or gr ea se. Before turning the engine of f, opera te the choke in[...]

66 MAINTENANCE Lubri cation n Chaincase Oil Level It’ s the operator’ s responsibility to che ck a nd maintain the pr oper chai ncase o il l evel . T o ch eck t he oi l lev el, p lace t he m achi ne on a l evel s urface. Th e oi l level should be betwee n the “safe ” marks on the dipstick (A). Add Polaris synthetic c hainca se oil through t[...]

67 MAINTENANCE Spar k Pl ugs A spar k plug with a hea t range too high will cau se engine damage . A spark plug w ith a he at range too low will ca use e xcessive fouling and engine malf unctioning. In sele cting a spa rk plug he at range for pr oduction, a manuf acture r assumes that the engine will be opera ted under extr eme hea vy duty conditio[...]

68 MAINTENANCE Spar k Pl ugs Spark plug c ondition is indicative of engine opera tion. The spar k plug firing end c ondition should be re ad a fter the engine ha s bee n warme d up and t he veh icl e has been d riv en at hi gh er speed s. Imm edi at ely check th e spark p lug fo r correct col or . W ARNING A hot exhaust syst em and engine can cause[...]

69 MAINTENANCE Intake Filter The intake f oam filter s limit snow ingestion into the intake system. When ope ra ting in loose powder snow , check the top of the foa m filters perio di call y t o remov e any accum ul ati on o f snow . CAUTION Operat ing t he snowmobile wit h t he intak e filt ers remov ed may cause c arburet or ic ing. T he result w[...]

70 MAINTENANCE V aria b le Exh au st Sy st em (VES) Maintena nce of the VE S i s limited to a periodic inspection and clea ning of system c omponents. Every 1000 to 2000 miles (800- 1600 km), bring the ma chine to a n authoriz ed Polar is dealer to have the VES di sass em bl ed, i nsp ected , and clean ed. NOT E: T o ens ure max imum per for mance [...]

71 MAINTENANCE Car bur etor The n um ber s tam ped in th e end of t he m ain jet i nd icat es t he j et s ize. The jet installe d at the time of manufactur e is not n eces sari ly co rrect for your ele vation. It’ s your dealer ’ s responsibility to make sur e the cor re ct main jet is installe d. CAUTION Operat ing t he snowmobile wit h incor [...]

72 MAINTENANCE Exhaust S ystem Check the e xhaust system for wear or da mage a t approximate ly 1000 miles (1600 km) . T o inspect, allow the e ngine a nd exhaust syste m to cool comple tely . Open the hood and inspec t the muf fler and pipes f or cracks or dam age. C heck for weak o r mi ssi ng ret ai ni ng sp rin gs o r damper /support gr ommets.[...]

73 MAINTENANCE Engi ne Cooli ng Coola nt Mixtur e The coolan t supplied in the system is a 50/50 mixture of ethylene -glyc ol and distilled w ater . This mixture provide s prote ction again st freezi ng at t emp eratu res to -3 4 ° F (-37 ° C). If great er prot ecti on is requ ired , th e percent age o f ant ifreeze t o wat er may be increas ed. [...]

74 MAINTENANCE Engi ne Cooli ng Flushing the Cooling Sy stem T o ensure tha t the coolant maintains its ability to protect the engine , the system should be complete ly drained e ver y two years a nd a fr esh 50/ 50 o r 60/ 40 mi xt ure of ant i freeze and dis tilled wa ter should be added. This servic e must be done when the engine is cold. Ask yo[...]

75 MAINTENANCE Engi ne Cooli ng Bleeding the Cooling System 3. T ip the snowmobile slightly onto its right side. Cycle the RPM from idle to e nough RPM (4000) to get coolant to flow , but not enough to enga ge the c lutch. This allows a ir to bleed f rom the re ar crossove r tube. NOT E: T here mus t be enough c oolant f low t o purge t he air f ro[...]

76 MAINTENANCE Drive Chain T ension T o ob tai n correct ch ain t ens io n: 1. Rotate the driven clutc h counter clockwise to move all chai n sl ack to t he ten si on er side. Lock the brake le ver lo ck, or h ave an ass is tan t h ol d the bra ke lever f irmly . 2. Loosen the adjuster bolt jam nut (A). 3. Fi nger tighten the adjuste r bolt (B) unt[...]

77 MAINTENANCE n Hydr aulic Br ake Inspection Freque ntly inspec t the brake l ever res erve. Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1.3 cm) . A smalle r di st ance i ndi cat es l ow brak e fluid leve l or air in the hydraulic syste m. Refer t o t he b rake bl eedi ng informa tion on page 80. Brak e p[...]

78 MAINTENANCE Br akes Br ake C ompone nts 1. B rake C ali per 2. C hai ncase 3. Brake Disc 4. Backing Plate 5. Brak e Pad M ateri al (R eplace when t hi ckn ess i s les s th an 1/ 16 ″ ). Excessive Br ake Lever T ravel Hydraulic br ake s are self- adjusting, but if excessive bra ke pad clea ranc e develops, as descr ibed on page 77, the machine [...]

79 MAINTENANCE Br akes Br ake Fl uid W ARNING Aft er opening a bot t le of br ake f luid, alway s disc ard any unus ed port ion. Never st ore or use a part ial bot tle. Brak e fluid is hygros copic, meaning it rapidly absorbs mois tur e from t he air . The m oistur e causes t he boiling tem perat ure of the br ake f luid to drop, which can lead t o[...]

80 MAINTENANCE Br akes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spongy brake le ver ac tion. Bleed the system befor e opera ting the snowmobile. W ARNING Oper ating t he vehicle wit h a spongy brak e lever c an result in loss of br akes, which c ould cause an ac cident and lead to s erious injury or death. N[...]

81 MAINTENANCE Headlights Headlight Adjustment The hea dlight may be adjusted for ver tical aim using the following proce dure: 1. P lace t he s nowm ob il e on a lev el s urface wi th th e headl i ght approxima tely 25 f ee t (7.6m) fr om a wa ll. 2. Measure the distanc e fro m the floor to the center of the hea dlight and m ake a m ark o n th e w[...]

82 MAINTENANCE Headlights NOT E: Do not touc h a halogen bulb with bar e finger s. Oil f rom s kin leaves a r esidue, c ausing a hot spot t hat will s hort en the lif e of t he lamp. Rem ovi ng Haloge n Bulbs - High/Low B eam 1. P inch the ends of the spring (1) togethe r an d lift until it re lea ses from t he s pri ng ret ain er . 2. Lift spring [...]

83 MAINTENANCE Clutch S ystem W ARNING If you bec ome aware of higher t han norm al clut ch engagement or an unusual vibr ation or shif t pat t ern, see your dealer imm ediately . Do not oper ate t he machine unt il repair s have been m ade. All clut ch m aintenanc e and repairs must be perf orm ed by an author ized Polaris dealer. Any unauthoriz e[...]

84 MAINTENANCE Clutch S ystem n Dr ive B elt Condi tion Periodic ally c hec k the condition a nd tension of the drive belt, and always c arr y a spare belt. For improve d drive-a way during e xtreme ly cold t emp eratu res, r emov e the belt an d warm it t o room t emp eratu re. Reinsta ll it befor e star ting the snowmobile. Drive B elt Removal 1.[...]

85 MAINTENANCE Clutch S ystem n Drive B elt Deflection Measu re bel t defl ecti on wi t h bot h clut ches at res t and i n th eir ful l neutra l position. Place a straight edge on the belt (A) and apply downwa rd pre ssure while measur ing at point B. This measur ement should be 1 1/4”. Dr ive B elt Adj ustme nt 1. Loosen the 7/6” jam nut on th[...]

86 MAINTENANCE T or que St op If your snowmobile is equipped with an engine torque stop ( 1), periodic ally ch eck tor que stop clearan ce. W it h clu tch es in proper a lignment, the torque stop clea ra nce should be a minimum of .010 ″ to a maximum of . 030 ″ from the engine ca se (2). Adjust if neces sary , and lo ck th e jam nut. Rever se K[...]

87 MAINTENANCE Chain T ension Maintain the prope r cha in tension as outline d on page 76. Fall T une -Up For maximum perfo rmanc e, arra nge for a fa ll servic e tune-up with your Po lari s deal er . His ex peri enced and t rai ned serv ice tech ni cian wi ll k eep your mac hine in pea k opera ting condition. T ool Ki t A too l ki t i s in clu ded[...]

88 MAINTENANCE T rack Maintenance W ARNING Moving par ts can cut and cr ush body par ts . W hen perf orm ing the check s and adjust ment s rec omm ended on the f ollowing pages, st ay clear of all mov ing parts. Never per for m tr ack meas urement or adjust ment s wit h the engine r unning. T rack T ensio n T rack adjustme nt is critica l for prope[...]

89 MAINTENANCE T rack Maintenance I f t he tr ac k nee ds adjust m ent ( co nti nued) : 8. Repeat measur ement on the other side of the track . NOT E: Check mor e fr equently when m achine is new . 9. Start the machine a nd slowly rotate the tr ack at lea st five revolutions. Let the trac k come to a stop (do not apply br akes) . 10. Ch eck track a[...]

90 MAINTENANCE T rack Maintenance T rack Inspection W ARNING Brok en tr ack r ods are a s erious s afet y haz ard. T hey c an cause a rot ating t rack t o come off the m achine, which could c ause ser ious injury or death. Never oper ate wit h a damaged t rac k. Never rot ate a dam aged tr ack under power . Using a hoist, safe ly lift and support t[...]

91 MAINTENANCE Steer ing System Steering Inspection and Adjustment Each week, or b efore a long ri de, ch eck all f ast eners and t ig ht en if necess ary . S peci fical ly ch eck fast eners m arked wi th a + .[...]

92 MAINTENANCE Steer ing System Sk i Ali gnment W ARNING Im proper ski alignment or adjust ment may caus e loss of steering contr ol, r esult ing in serious injury or deat h. Do not at tem pt t o change the s ki alignm ent or camber adjust ment . S ee your Polaris dealer. W ith the handleb ars in a str aight ah ead position, and w ith vehic le weig[...]

A 93 MAINTENANCE Steer ing System n Ski S kags W ARNING Worn skis and/ or skags will adver sely affec t handling. Los s of vehicle cont rol may r esult , causing ser ious injury or deat h. See your dealer ’s studding c hart for recom mended s kags. If you install longer or m ore aggres sive c arbide sk ags t han the or iginal equipment , it may a[...]

A 7/16 ″ (1.1 cm) 94 MAINTENANCE Suspension Maintenance n Slider W ear Measur e slider thic kness at sever al points along the rail. Have your de aler re place the slide r whe n it’ s w o r nd o w nt ot h et o po f the wear gr oove (A). Do not operate the snowmobile if slider thic kness me asure s less than 7/16 ″ (1.1 cm ). n Pr e - Ride S u[...]

95 MAINTENANCE Extended S tor age Of f-se ason or extende d storage of your snowmobile requir es preve ntive measur es to a id against dete riora tion and to pr olong the usef ul life of many co mponents. Cleaning and Preser vation Proper stor age sta rts with clea ning, washing, and waxing the hood, chass is , an d pl ast ic part s. W ipe do wn re[...]

96 MAINTENANCE Extended S tor age Engi ne and Car bur etor P rotec tion Proper pr epar ation of the engine a nd fue l system is vital to the preve ntion of rust a nd corr osion on prec ision engine pa rts during st orage. When ever t he m achi ne i s s to red fo r a peri od o f m ore t han 6 0 days,the engine must be fogged with fogging oil. Follow[...]

97 MAINTENANCE Extended S tor age Electr ical Connections Sep arate elect rical con nect or bl ocks an d clean co rros ive bu il d-u p from conn ecto rs. Lub ricat e or p ack co nnect or b lo cks wit h d iel ectri c greas e and re- connec t. See page 99 for the part numbers of Polaris products. Repl ace worn or frayed elect rical wire an d con nect[...]

98 MAINTENANCE T ranspor ting the S nowm obile Whe neve r the snowmobile is transpor ted: 1. T urn the fuel valve clockwise to OFF to shut of f the fuel supply (1). Tu r n t h e v a l v e counter -clockwise to ON to turn the f uel supply on (2). NOT E: T h ef u e lv a l v ei s located under t he hood. 2. Be sure the fuel ca p is installed corr ec t[...]

99 POLARIS PRODUCTS Part No. Descrip ti o n Engine Lubr icant s 2870791 Fogging Oi l ( 12 oz. Aerosol) 2873023 Synthet ic 2- Cycle Raci ng Oi l ( gal. ) Chaincase Lubr icant s 2873105 Synthet ic Chaincase Lubri cant (qt .) 2872951 Synthet ic Chai ncase Lubri cant ( 12 oz.) Grease / Speci ali zed Lubricant s 2871312 Grease G un Kit , Pr emium All Se[...]

100 TROUBLE S HOOTING Engine T roubleshooting CAUTIO N: Unless you have e xperie nce a nd training in two-c ycle engine re pair , see your dealer if te chnic al problems ar ise. Proble m Proba ble C aus e Solutio n Err a ti c e ngine oper a ti ng RPM du rin g accelera- tion or lo ad var i at i ons Driv e clutch bin d in g Driv en clu tch malfu ncti[...]

101 TROUBLE S HOOTING Engine T roubleshooting Proble m Proba ble C aus e Solutio n Noise i n drive system Broke n drive c l utc h com ponent s Bearin g failu re/ chain case, jack sh aft, or fr ont dri ve s haf t Driv e b elt su rface flat spot s Driv e chain loo se or worn, s pr oc ket t e et h broke n -SEE YOUR DEALER. -SEE YOUR DEALER. -Insp ect [...]

102 TROUBLE S HOOTING Engine T roubleshooting Proble m Proba ble C aus e Solutio n Engine t ur ns bu t fails to start Fau lty ig nitio n No fue l t o engi ne Floode d engi ne (nor - mal situ atio n cau sed by too m uch c hok- ing) Poor engi ne c ompre s - sion -Rem o ve sp ark plu g (s) an d replace w ith new plu g (s). If engi ne still fails to st[...]

103 TROUBLE S HOOTING Suspension T r oubleshooti ng Proble m Solution (per form only one c hange a t a tim e) Rear su sp en sio n bo tto ms to o easily -I nc re a se tors i on spr i ng pre l oad -I nc re a se rea r s hock c ompr e ss i on dam ping by t ur ning s c re w cl oc kwi se -I nc re a se t or si on spr ing wir e di am et e r (s e e your dea[...]

104 TROUBLE S HOOTING Belt T r oubleshooti ng Belt W ear/Burn Be lt W ea r/B urn Dia gnos is Causes Solut ions Driv ing at low RPM Dri ve a t highe r RPMs . Ge ar t he ma chi ne down. Che ck bel t def l ec t ion. Insu fficient w arm-u p W a rm the e ngi ne at l e as t f ive mi nut es . T a ke the dr ive be l t of f the mach in e in extremely co ld [...]

105 WARRANTY Ser vic e And Warranty I nform ati on Obtaining Service and W arranty Assistance Read and unde rstand the ser vice data a nd the Polaris warr anty informa tion containe d in this manual. Contact your Polaris dea ler f or replacem ent part s, s ervi ce or warrant y . Y our d ealer recei ves frequ ent updates on c hange s, modifications [...]

106 WARRANTY Li mit e d W arra nt y Pola r is Sa l es Inc. , 2100 Highwa y 55, Medi na , MN 55340, provi de s a ONE YEAR LIM - ITED W ARRANTY on all c ompone nts of t he Pola r is s nowmobi le a ga ins t de fe c ts i n ma te r ia l or wor kmans hi p. This wa rr a nty cove r s the pa r ts a nd la bor cha r ges for r e pai r or replacem en t o f d ef[...]

107 WARRANTY Limita tions of warranti es a nd remedie s ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TICU- LAR PURPOSE) ARE LIMI TED IN DURA TI ON TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RA NT IE S NO T S T A TE D IN T HIS[...]

108 WARRANTY Conditions and Ex cl usi ons In or de r t o qua li f y for wa r ra nty , t he produc t mus t ha ve be en pr ope rl y s et up and te s te d by a Po laris D ealer (if ap plicab le). F ailu re o f an y d ealer to perfo rm th e req u ired veh icle Pre - - De li ve ry Ins pec t ion, pe r for m al l appl i ca bl e se r vic e bul le t ins a n[...]

109 WARRANTY Pol ari s Se cond Y ear E ngine Se rv ice Contr ac t Sec ond Y e ar Engi ne Se r vic e Cont ra c t i s s ta nda rd on a ll eli gi ble ne w a nd unuse d snow mobil e s t ha t we r e Snow Che cke d t hrough a n a uthor iz e d Pol ar is deal e r dur i ng the Ma rc h/ Apri l Snow Chec k promoti on. The fr e e Sec ond Y ear Engi ne Se rvi c[...]

11 0 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t f rom Pola r is [...]

111 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS 150 mi. (240 km ) 500 mi. (800 km ) 1000 mi. (1600 km) 2000 mi. (3200 km)[...]

11 2 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 3 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 4 INDEX A Accesso ries 3 8 -4 1 .................. A v alan ch es 1 3 .................... B Bef or e Sta rt i ng the Engi ne 43-46 ...... Bel t T roubl e shoot i ng 104 ........... Ble e ding t he Cooli ng Sys te m 67, 74-75 . Bleed in g t he H y d raulic B rak e S ystem 80 Bra ke Compone nt s 78 .............. Brak e F luid 79 ................[...]

11 5 INDEX M Ma int e nanc e I nte r val T abl e 60-62 ...... Ma int e nanc e Pr ogra m 59 ............ Ma int e nanc e Re c ord 11 1- 1 13 ......... Man euv erab ility 16 ................ O Oil R ec omme nda t ions 49 ............ Op eratin g Area 47 ................. Ope ra t ion W ar ning 22-23 ............ Ope ra tor Sa f et y 7-19 ............[...]