Polaris FS Classic User's Manual

WARNING
Read, understand, and follow all of the instructions
and safety precautions in this manual and on all
product labels.
Failure to follow the safety precautions could result
in serious injury or death.
PROPOSITION 65
WARNING
Snowmobile engines discharge fuel
and exhaust, which contain chemicals
known to the State of California to
cause cancer and birth defects or other
reproductive harm, onto the snow on
which they operate. Keep this engine
properly tuned and avoid unnecessary
idling and spillage during fueling.
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 FS/FST Classic/Touring & FST Switchback Owner’s Manual P/N 9919670
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . . . 64
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133
134
141
149
152
3
4
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when the snowmobile
is sold.
Some of the illustrations and photos used in this manual are general
representations. Your model may differ.
Follow the maintenance program outlined in this manual. Preventive
maintenance ensures that critical components of the snowmobile are
inspected by your dealer at specific mileage intervals.
You and your dealer must complete the registration form included with
your snowmobile and forward it to us. This completed form is
necessary to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
5
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may
not be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
6
INTRODUCTION
Vehicle 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.
Your 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.
L
Vehicle Model Number:
Tunnel VIN (L):
Engine Serial Number (on valve cover):
Key Number:
7
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
8
Operator Safety
SAFETY
Follow the recommended maintenance program outlined beginning on
page 87 of this manual to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific
mileage intervals.
WARNING
Driving a snowmobile requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving or
riding as a passenger. They will reduce your alertness and slow
your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra
caution to ensure operator safety. Make sure your snowmobile is
in excellent operating condition at all times. Always check major
and vital safety components before every ride.
All Polaris snowmobiles are designed and tested to provide safe
operation when used as directed. Failure of critical machine
components may result from operation with any modifications,
especially those that increase speed or power. DO NOT
MODIFY YOUR MACHINE. The snowmobile may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.
9
SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation.
WARNING
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 snowmobile up or
stand behind it while warming up
the track. A loose track or flying
debris could cause serious injury or
death. We recommend having your
dealer perform all track service and
alignment procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Turn off the
ignition, raise the hood, make the adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting
adjustments.
10
Operator Safety
SAFETY
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under many conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING
Improper riding position may reduce control and could result in
serious injury or death. Always ride in a position that allows for
control of your vehicle.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular telephone.
For added protection, carry the following items on your snowmobile at
all times:
SSpare Drive Belt
SExtra Set of Spark Plugs
STow Rope
SExtra Oil
SFuel Deicer
SWinter Survival Kit
STrail Map
SOwner’s Manual
SFirst Aid Kit
STool Kit
11
SAFETY
Operator Safety
Riding Apparel
Be prepared, be warm and be
comfortable when riding. Be
aware of the weather
forecast, especially the
windchill, and dress
accordingly. See the chart
on page 22.
WARNING
Avoid wearing loose
clothing or long
scarves, which can
become entangled in
moving parts and
cause serious injury.
Always wear an
approved helmet and
eye protection.
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have
an increased risk of loss of control, which could result in serious injury
or death.
Cargo Overload (Touring)
Too much weight on the rear of the machine may reduce your ability to
steer. Do not exceed carrier and rack weight limits, and do not allow a
passenger to sit on the seat back or the cargo carrier.
12
Operator Safety
SAFETY
Rider Capacity
Driving 1-Up - Some Polaris snowmobiles are designed for a single
rider only. A decal on the console of these models 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 one operator and one passenger only.
WARNING
Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed
for stopping. Make sure the passenger remains seated behind
the driver, facing forward, with both feet placed firmly on the
running boards. Slow down and avoid “jumping” your
snowmobile.
Snowmobiles designed for two riders should never be operated with
more than two people on board. When traveling with a passenger, it’s
the driver’s responsibility to operate the snowmobile safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are
necessary for stopping.
13
SAFETY
Operator Safety
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious
injury or death. Always reduce speed when driving at night or in
inclement weather.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the
trail ahead. Multiplying speed (MPH) by 1.5 will equal the
approximate number of feet per second your snowmobile travels. If
your speed is 40 MPH, your snowmobile is traveling about 60 feet per
second. If you look back for only two seconds, your snowmobile will
travel about 120 feet. If your speed is 60 MPH, your snowmobile will
travel about 180 feet in two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t over-drive your headlight beam.
Always be able to bring your snowmobile to a stop in the distance
illuminated by the headlight.
14
Operator Safety
SAFETY
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you’re snowmobiling 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 distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your snowmobile will drown
out the sound of approaching vehicles.
Look ahead, behind, and to both sides
before turning or crossing railroad tracks
or highways. Steep embankments may
also hide your view. Always leave
yourself a way out.
Variances in snow depth and/or water
currents may result in uneven ice
thickness. You may drown if you break
through the ice. Avoid travelling on frozen bodies of water.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
15
SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
S Take an avalanche class
S Travel with experienced people
S Travel on designated trails
S Make sure each person is equipped with
a shovel, probe and avalanche beacon.
You don’t have to be snowmobiling on a slope for an avalanche to
occur. Be aware that all of the snow is connected. You may be riding
on a flat slope or snow covered road, but if the snowpack above is
unstable enough you can trigger an avalanche on a steeper slope above
you. Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit either
the American Avalanche Association online at
www.americanavalancheassociation.org or the U.S. Forest Service
National Avalanche Center at www.avalanche.org.
16
Operator Safety
SAFETY
Ice and Snow Build-up
WARNING
Ice and snow build-up may interfere with the steering of your
snowmobile, resulting in serious injury or death. Keep the
underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure
ice and snow are not interfering with full left and right steering. If
difficulty is encountered, remove ice and snow build-up that may be
obstructing the steering linkage.
NOTE:
If your snowmobile is equipped with RIDER SELECT,
perform this check in both the full up and full down steering
positions.
Driving Downhill
When riding downhill, shift your weight to the rear of the snowmobile
and reduce your speed to a minimum. Apply just enough throttle to
keep the clutch engaged, allowing the engine’s compression to help
slow the snowmobile and keep it from rolling freely downhill.
WARNING
When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.
17
SAFETY
Operator Safety
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution.
Driving on ice or hard-packed snow reduces steering and braking
control, which may result in loss of control and serious injury or
death. Slow down and use extra caution when operating on
slippery surfaces.
Driving in Hilly Terrain
WARNING
Climbing a hill or crossing the face of a slope may result in loss of
balance and snowmobile rollover, causing serious injury or death.
Use caution and good judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the snowmobile
to maintain proper balance and avoid possible rollover.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops or other people or vehicles that may be on the
other side of the hill.
If you’re unable to continue up a hill, turn the snowmobile downhill
before it loses momentum. If this isn’t possible, spin the track just
enough to dig in to prevent it from rolling back down the hill. Stop the
engine and set the parking brake (if equipped). Keeping away from the
downhill side of the snowmobile, pull the rear of the snowmobile
around and point the front end and skis downhill. Remount the
snowmobile, restart the engine, release the parking brake, and descend
the hill carefully.
18
Operator Safety
SAFETY
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation 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 removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is
dynamically balanced before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the snowmobile into motion, but always
operate within safety limits and, on 2-Up machines, with respect for a
passenger.
Maneuverability
While much control and maneuverability is achieved through the
steering system and skis, maximum control is achieved by the shifting
of your body weight. Maneuverability will change for lighter operators
or snowmobiles designed to carry a load or a passenger.
19
SAFETY
Operator Safety
Inadequate Snow Conditions
Since snow provides the only lubrication for the power slide
suspension and, on liquid cooled models, cooling for the engine,
adequate snow cover is a requirement for operation of your
snowmobile. Driving in too little snow will result in excessive wear
and damage to the slide rail, track and/or engine.
WARNING
Inadequate cooling and lubrication will lead to overheating of the
slide rail and track, causing premature wear, damage and failure,
which can result in serious injury. Reduce speeds and frequently
drive into fresh snow to allow adequate cooling and polishing of
the slide rail and track surfaces. Avoid operating for prolonged
periods on ice, hard-packed surfaces or roads.
Operating in Deep Snow
If the snowmobile becomes stuck in snow, clear the running board area
of snow, then step down the snow in front of the snowmobile so that
when the throttle is opened, the snowmobile will be able to climb up
and over the snow.
20
Operator Safety
SAFETY
Driving Responsibly
Every snowmobile handles differently, and even the most docile
conditions may become dangerous if operators drive improperly. If
you’re new to snowmobiling, acquaint yourself with the snowmobile
and with what it will and won’t do under various conditions. Even
seasoned drivers should spend some time getting the feel for a
snowmobile before attempting ambitious maneuvers.
S A snowmobile depends on the rider’s body position for proper balance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
S Before allowing someone else use your snowmobile, know the extent of their operating skills. Check to see if they’ve taken a snowmobile safety course and have an operator’s certificate. For their
protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.
S Don’t “jump” your snowmobile. Jumping may injure your back because of spinal compression. The seat and suspension of your snowmobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.
S Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
S When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow
and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions.
Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.
S Remove the key from the ignition when you leave the snowmobile
unattended.
21
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when
temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
in
MPH
Actual Thermometer Reading (°F)
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-25
-30
-35
-40
-45
-20
-34
-41
-45
-48
-51
-53
-55
-57
-58
-60
-61
-62
-25 -30
-40 -46
-47 -53
-51 -58
-55 -61
-58 -64
-60 -67
-62 -69
-64 -71
-65 -72
-67 -74
-68 -75
-69 -76
5 min.
-35
-52
-59
-64
-68
-71
-73
-76
-78
-79
-81
-82
-84
-40
-57
-66
-71
-74
-78
-80
-82
-84
-86
-88
-89
-91
-45
-63
-72
-77
-81
-84
-87
-89
-91
-93
-95
-97
-98
-31
-34
-37
-40
-43
-46
-31
-39
-43
-45
-47
-49
-50
-51
-52
-53
-54
-55
-55
-34 -37
-43 -46
-47 -50
-49 -53
-51 -55
-53 -57
-54 -58
-55 -59
-56 -61
-57 -61
-58 -62
-59 -63
-60 -64
5 min.
-40
-50
-54
-57
-59
-61
-62
-64
-65
-66
-67
-67
-68
-43
-53
-58
-61
-63
-65
-66
-68
-69
-70
-71
-72
-73
-46
-57
-62
-65
-67
-69
-70
-72
-73
-74
-75
-76
-77
Equivalent Temperature (°F)
Calm
5
10
15
20
25
30
35
40
45
50
55
60
40
36
34
32
30
29
28
28
27
26
26
25
25
35 30 25
31 25 19
27 21 15
25 19 13
24 17 11
23 16
9
22 15
8
21 14
7
20 13
6
19 12
5
19 12
4
18 11
4
17 10
3
Frostbite in >>
20
13
9
6
4
3
1
0
-1
-2
-3
-3
-4
15
7
3
0
-2
-4
-5
-7
-8
-9
-10
-11
-11
10
5
1
-5
-4 -10
-7 -13
-9 -15
-11 -17
-12 -19
-14 -21
-15 -22
-16 -23
-17 -24
-18 -25
-19 -26
30 min.
0
-5
-11 -16
-16 -22
-19 -26
-22 -29
-24 -31
-26 -33
-27 -34
-29 -36
-30 -37
-31 -38
-32 -39
-33 -40
10 min.
-10
-22
-28
-32
-35
-37
-39
-41
-43
-44
-45
-46
-48
-15
-28
-35
-39
-42
-44
-46
-48
-50
-51
-52
-54
-55
WIND CHILL CHART (°C)
Wind
Speed
in
KPH
Actual Thermometer Reading (°C)
5
2
-1
-4
-7
-10
-13
-16
-19
-22
-25
-28
Equivalent Temperature (°C)
Calm
8
16
24
32
40
48
56
64
72
80
88
96
22
5
3
2
1
0
-1
-1
-2
-2
-2
-3
-3
-3
2
-1
-4
0
-7
-2 -6 -10
-3 -7 -11
-4 -8 -12
-5 -9 -13
-5 -9 -13
-6 -10 -14
-6 -10 -15
-7 -11 -15
-7 -11 -15
-7 -12 -16
-8 -12 -16
Frostbite in >>
-7
-11
-13
-15
-16
-17
-18
-18
-19
-19
-20
-20
-21
-10
-14
-17
-19
-20
-21
-22
-22
-23
-23
-24
-24
-25
-13 -16
-18 -22
-21 -24
-22 -26
-24 -28
-25 -29
-26 -30
-26 -31
-27 -31
-28 -32
-28 -33
-29 -33
-29 -34
30 min.
-19 -22
-25 -29
-28 -32
-30 -34
-32 -36
-33 -37
-34 -38
-35 -39
-35 -40
-36 -40
-37 -41
-37 -42
-38 -42
10 min.
-25
-32
-36
-38
-39
-41
-42
-43
-44
-45
-45
-46
-47
-28
-36
-39
-42
-43
-45
-46
-47
-48
-49
-50
-50
-51
Safety Decals and Locations
SAFETY
Warning decals have been placed on the snowmobile for your
protection. Read and follow the instructions of the decals and other
warnings on the snowmobile carefully. If any of the decals depicted in
this manual differ from the decals on your snowmobile, always read
and follow the instructions of the decals on the snowmobile.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found
under the hood on the clutch
cover:
Warming
Do not operate with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with plenum/belt guard
removed.
Never run engine with drive belt removed.
Never service clutches yourself. See your dealer.
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of
applicable liquid cooled models:
Warming
Do not open hot. Test or replace when changing
coolant. Press down and turn to release cap. 13
PSI
23
SAFETY
Safety Decals and Locations
“No Passenger” Warning
Snowmobiles designed for a
single rider only have a
warning decal on the console
below the steering post:
Warming
This vehicle is designed for
operator only.
“NO PASSENGER”
+
Passenger Warning
Snowmobiles designed for an operator and one passenger have a
warning decal at the right side of the steering post. For more
information on operating with a passenger, see page 13.
Warming
This vehicle is designed for
operator and “ONE” passenger only.
Track Warning
Warming
Stay clear of track. Do not sit on
seat back. Entanglement with the
track or a fall from seat back may
result in severe injury or death.
+
24
SAFETY
Safety Decals and Locations
+
+
Reverse Warning
Reverse operation, even at low speeds, may cause loss of control
resulting in serious injury or death. To avoid loss of control,
always:
S
S
S
S
Look behind before and while backing.
Avoid sharp turns.
Shift to or from reverse only when stopped.
Apply throttle slowly.
NOTE: For more information, see Owner’s Manual.
If electric reverse:
S Machine stopped and engine at idle, push yellow button on LH
control to reverse. Flashing light on dash indicates reverse operation.
S Push button again to return to forward.
25
SAFETY
Safety Decals and Locations
Operation Warning
S To avoid serious injury or death,
read and understand all warnings
and the Owner’s Manual before
operation. If the manual is missing, contact a Polaris dealer for a
+
+
replacement.
S This vehicle is capable of high
speeds. Buried objects or uneven terrain can cause loss of
control. Reduce speed and use
extreme caution when operating
in unfamiliar terrain.
S Excessive speed, especially at
night or with limited visibility, can
result in insufficient time for you
to react to terrain changes, to avoid unexpected obstacles, or to stop safely.
S Never consume alcohol or drugs before or while operating this vehicle.
S In an emergency, push down the Auxiliary Shut-Off Switch, located on the top
of the throttle control assembly, to stop the engine. Then pull the brake lever
to stop.
S Always wear an approved helmet, eye protection, and adequate clothing
while operating this vehicle.
S This vehicle is designed for adult use only. Check local laws for age requirements.
S When operating with a passenger (on approved models only) reduce speed
and allow extra space for steering and stopping. A passenger reduces your
ability to control the vehicle.
S When operating on hard-packed snow, ice, or when crossing roads, steering
and braking ability are greatly reduced. Reduce speed and allow extra space
to turn or stop.
S To maintain vehicle control on ice or hard-packed surfaces, you should have
a proper balance of ski carbides to track studs. See Owner’s Manual for
proper use of traction products.
S Repeated stops from high speed may cause fading or sudden loss of braking
ability.
S Parking brake may relax when used for long periods. Do not leave brake
engaged for more than five minutes.
S Before starting engine, check throttle, brake, and steering for proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when refueling.
26
FEATURES
4
10
9
11
8
7
5
6
3
12
2
13
1
14
15
18
16
17
1.
2.
3.
4.
5.
6.
7.
8.
9.
Front Bumper
Hood
Headlight
Passenger Lumbar Adjuster
(Touring)
Windshield
Handlebar
Operator Seat
Passenger Seat (Touring)
Passenger Grab Handle
10. Grab Handle Heater Switch
(Touring)
11. Trunk Cover or Storage
Compartment
12. Taillights
13. Rear Bumper
14. Snow Flap
15. Track
16. Suspension
17. Skis
18. Nosepan
27
FEATURES
16
6
7
8
5
4
9
10 11
12
13
3
15
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
28
14
1
Fuel Filler Cap
Rider Selectt
Ignition Switch
Handlebar hook
Brake Lever
MFD (Multi-Function Display)
Engine Stop Switch
Throttle Control
Hood Hold Down Straps
10. Parking Brake
11. Handlebar Grip Warmer
Switch
12. Thumbwarmer Switch
13. Electronic Reverse Button
14. MFD Control
15. Headlight Dimmer Switch
16. Mountain Bar (if equipped)
FEATURES
Passenger Seat (Touring)
The passenger seat features an adjustable lumbar
support. To adjust for rider comfort, rotate the
lumbar adjustment knob (A).
A
Storage Compartments
Trunk (Touring)
Open the trunk cover (B) to access the rear storage compartment. The
passenger seat and trunk cover are removeable to provide open storage
for transporting larger items.
B
1. Remove the
trunk cover.
C
2. Push down on the seat
latch lever (C), which
is located at the lower
rear of the passenger
seat.
3. Lift up the seat and
remove it from the chassis.
4. Reverse the procedure to reinstall the seat and trunk cover.
Under-Seat Storage (Switchback)
Lift the seat lever (+) and lift the
seat to access the under-seat storage
area.
+
Storage Compartment (Classic)
Open or close the storage
compartments with the key.
29
FEATURES
Radiator Compartment
Access Panel
The access panel (+) is provided
for cleaning debris from the
radiator.
+
Cargo Rack (Switchback)
The maximum weight capacity
for the cargo rack (+) is 15 lbs.
(7 kg). Always secure cargo
before operating. Do not exceed
the rack weight limit. Do not
allow a passenger to sit on the
seat back or the cargo rack.
Adjustable Headlights
Adjust the headlight beam by
moving the adjuster to the left
or right.
30
+
FEATURES
RIDER SELECT Adjustable Steering System
The RIDER SELECT adjustable steering system allows you to adjust
the handlebar position to fit your style of riding. Some models have
five (5) adjustment positions. Other models have seven (7) positions.
WARNING
If your snowmobile has five adjustment positions, do not remove
the RIDER SELECT lockout. Your Polaris snowmobile has been
engineered for this range of adjustability. Removing this lockout
and using RIDER SELECT position 6 or 7 will result in the
handlebars and brake lever contacting other components and
interfering with steering and braking. This could lead to loss of
control resulting in serious injury or death. Always be sure that
the handlebars and brake lever do not contact any other
snowmobile components at any steering position AND at any
RIDER SELECT position.
Do not use RIDER SELECT positions 6 or 7 unless riding
conditions require it. Operation in positions 6 or 7 can reduce
vehicle handling for other types of riding and result in serious
injury or death.
Choosing the Best RIDER SELECTt Position
Position
Riding Style
1
2
3
Relaxed Trail Riding
4
5
General Trail Riding, Boondocking,
Deep Snow Riding
6
7
Snowcross/Steep Hill Climbing Only
Rider weight is slightly behind the center
of the snowmobile for comfortable and
relaxed riding.
Rider weight is centered on the snowmobile, providing balance, comfort and
control for both novice and experienced
riders. This is the recommended position for most riding situations.
Rider weight is ahead of the center of
the snowmobile, adding weight to the
skis and making the snowmobile heavier
in the front. These positions are ONLY
for snowcross and severe hill climbing.
31
FEATURES
RIDER SELECT Adjustable Steering System
Adjusting RIDER SELECT
WARNING
Attempting to adjust the handlebar position while the snowmobile
is moving could result in loss of control and serious injury or
death. Always stop the snowmobile before attempting to adjust
the steering system.
1. Stop the snowmobile.
2. Press the release button and
move the handlebar forward or
rearward to the desired
position.
WARNING
Do not lubricate the RIDER SELECT mechanism. Doing so could
cause loss of control and result in serious injury or death. The
RIDER SELECT mechanism is lubricated for life at the factory.
WARNING
Some aftermarket accessories (including windshields and cargo
bags) may interfere with the handlebar. Such accessories could
limit your ability to steer the vehicle and/or may contact the brake
lever. This could lead to loss of control resulting in serious injury
or death. Always be sure that accessories do not contact the
handlebar or brake lever at any steering position and at any
RIDER SELECT position.
32
Engine Management System
FEATURES
Malfunction Indicator Lamp (MIL)
The MIL (Check Engine Indicator) will illuminate when the ECU
detects a problem with engine management system components. If this
occurs, see your dealer for service immediately.
The MIL will blink in the event that the ECU detects an error with the
turbo boost regulation system. This may be caused by damaged or
disconnected hoses between the turbocharger and wastegate solenoid
pulse valve (located on the engine side of the airbox) or between the
wastegate actuator (located under the turbocharger) and wastegate
solenoid pulse valve. If the hose has no damage and is not
disconnected, see your dealer immediately.
CAUTION
Serious engine damage may occur if the wastegate reference line
is removed or modified. DO NOT remove or modify the
wastegate reference line.
33
FEATURES
Engine Management System
To protect the engine, the engine management system will limit engine
RPM, vehicle speed or turbo boost (FST) if the following conditions
are encountered.
Vehicle Speed is Limited
Cause
Function
Maximum
Speed
Reverse is selected
Reverse
12 (19)
Defective rollover switch
Rollover
37 (59)
Throttle stuck, throttle
lever depressed
Throttle stuck, throttle
safety switch high
18 (29)
Throttle safety switch
failure
Throttle safety switch
fault
31 (50)
Maximum vehicle speed
Max speed limiter
186 (299)
Result
MPH (km/h)
Engine will misfire
at higher vehicle
speed
Engine Speed is Limited
Cause
Function
Maximum
Result
RPM
Reverse is selected,
speed sensor error
Reverse
5300
Defective rollover switch,
speed sensor error
Rollover
6000
Throttle stuck, throttle
lever depressed, speed
sensor error
Throttle stuck, throttle
safety switch high
5450
Throttle safety switch
failure, speed sensor error
Throttle safety switch
fault
6200
Throttle stuck, throttle
lever at idle position
Throttle stuck, throttle
safety switch low
2400
Maximum vehicle speed,
speed sensor error
Max speed limiter
8800
Reverse failure
Reverse
2500
34
Engine will misfire
at higher engine
speed
ECU cannot determine whether
reverse or foward
is selected
Engine Management System
FEATURES
Engine Overheats (FS)
Indication
Flashing
g
overheat
h
lamp
l
Flashing
g
overheat
h
lamp
l
with
engine
g
misfire
At Vehicle
Speed
At Engine
MPH (km/h)
° F (° C)
0-31 (0-50)
230 (110)
Explanation
Temp
32-46 (51-74)
230-221 (110-105)
47-62 (75-100)
221-212 (105-100)
Above 62 (100)
212 (100)
0-31 (0-50)
239 (115)
32-46 (51-74)
239-230 (115-110)
47-62 (75-100)
230-221 (110-105)
Above 62 (100)
221 (105)
Lamp
p flashes when
engine
i temperature
exceeds table values
Lamp
p flashes and
engine
i misfires
i fi
when
h
engine temperature
exceeds table values
Engine Overheats (FST)
Indication
Flashing
g
overheat
h
lamp
l
Flashing
g
overheat
h t lamp
l
with
engine misfire
At Vehicle
Speed
At Engine
MPH (km/h)
° F (° C)
Explanation
Temp
0-31 (0-50)
221 (105)
32-46 (51-74)
221-212 (105-100)
47-75 (75-120)
212-203 (100-95)
Above 75 (120)
203 (95)
0-31 (0-50)
239 (115)
32-46 (51-74)
239-230 (115-110)
47-75 (75-120)
230-221 (110-105)
Above 75 (120)
221 (105)
Lamp
p flashes when
engine
i temperature
exceeds table values
Lamp
p flashes and
engine
i misfires
i fi
when
h
engine temperature
exceeds table values,
operator may feel
loss of power
Turbo Boost is Limited (FST)
Indication
Result
Illuminated overheat lamp
Engine coolant temperature is at or below 122° F (50° C) OR
Engine coolant temperature is at or above 203° F (95° C)
Operator may feel
loss of power
Intake manifold air temperature is at or below 32° F (0° C) OR
Intake manifold air temperature is at or above 158° F (70° C)
Overboost condition occurs (CHECK ENGINE MIL lamp will flash)
Fuel octane is too low (use the recommended fuel)
35
FEATURES
Detonation Elimination Technology (DET)
(Turbo Models)
A detonation sensor monitors the engine and responds to detonation by
automatically reducing the engine timing and adding fuel. This results
in decreased engine RPM and performance.
NOTE:
Engine performance will be reduced if fuel with a lower
octane than 91 is used. See fuel recommendations on
page 79.
Effect of DET
The DET system prevents damage to the engine from detonation while
developing the maximum power of the engine safely. If the system
senses detonation beyond a preset limit, it retards ignition timing and
adds fuel to reduce the detonation and prevent engine damage.
When the detonation returns to a permissible level, the system will
return spark and fuel to normal, allowing the engine to run at rated
power levels.
Sensor Fail-Safe
The DET includes a sensor fail-safe system to prevent the engine from
damage if the sensor fails, becomes disconnected or is unable to detect
detonation. The rider will experience a loss in power. The sensor must
be reconnected or repaired to regain full power.
NOTE:
36
The check engine light will illuminate if the sensor fails or
becomes disconnected.
FEATURES
Instrumentation
MFD Component Identification
Item
2
1
1 Analog Gauge
2 Digital Gauge
3 Check Engine Indicator
4 High Temp Indicator
5 Brake Indicator
6 Reverse Indicator
3
4
7 High Beam Indicator
5
6
7
Digital Display Identification
Item
1 RPM or Speed
Altitude (if equipped)
Service Interval
1
2
2 Electrical System Voltage
Level
3 MAX - Maximum MPH/
KPH or RPM
MPH - Miles per hour
KPH - Kilometers per hour
RPM - Engine crankshaft
revolutions per minute
4 Air Temp (if equipped)
Engine Temp
Degrees Celsius
Degrees Fahrenheit
5 Miles
Kilometers
6 Hours
Trip 1/Trip 2/Trip F
Service Label
Altitude Label
3
4
5
6
7
7 Fuel Level (FS) or Turbo
Boost (FST)
37
FEATURES
Instrumentation
MFD Settings
MFD settings can be made with the
A
engine running or with the engine off.
If the engine is off, make sure the stop
switch is pressed down and turn the
ignition key to the START position
briefly to activate the gauge. The gauge
will illuminate for about 90 seconds.
Use the MFD Control Switch (A) to set
B
C
the MFD display to your preference.
The rocker switch has a MODE button (B) and a SET button (C).
Standard vs. Metric
The MFD will display either standard or metric units of measurement.
While viewing a screen that displays measurements (MPH, KPH or
temperatures), press and hold the MODE switch until the unit of
measurement changes (about 10 seconds).
Speedometer/Tachometer
The speedometer and tachometer can be viewed in either the analog or
the digital display. If the analog display is set to show speedometer
readings, the digital screen will automatically display the tachometer
(option 1). If the analog is set to show the tachometer, the digital
screen will show the speedometer (option 2).
To change preferences, press and hold the MODE button for three
seconds. When the button is released, the new setting becomes active
and screen colors change. See table below.
Option
Analog
Display
Digital
Display
Analog
Screen
Digital
Screen
1
Speed
RPM
Blue “mph”
Blue
Backlight
2
RPM
Speed
Red “X100rpm”
Red
Backlight
38
Instrumentation
FEATURES
MFD Digital Display Programs
Press the MODE button to cycle through the three MFD programs:
Performance, Engine and History. Each program will remain in the
display until another is selected.
NOTE:
The analog will always display either MPH or engine RPM
(whichever setting is selected) regardless of the display
program being viewed.
Performance Program
The Performance Program automatically displays either speed or
tachometer, whichever is opposite the analog display. See page 38. It
also displays electrical system voltage and fuel levels.
While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F and Clock settings.
Trip Settings
Trip 1 and Trip 2 are odometers used to
check fuel mileage or to keep track of
distance traveled.
1. To reset a trip odometer to zero,
enter the Trip 1 or Trip 2 display.
2. Press and hold the SET button for
two seconds.
Trip F automatically displays if the fuel
level is low. The fuel symbol and the
last fuel bar on the MFD gauge will
blink when the fuel level reaches 1/8th
tank. The Trip F odometer records
distance traveled until enough fuel is
added to raise the level above 1/4 tank.
The fuel symbol and the fuel bar will
continue to blink until the fuel level is
above 1/4 tank. The Trip F odometer
will automatically reset to zero after
refueling.
Odometer Setting
The odometer records the vehicle’s
total distance traveled since
manufacture. The odometer cannot be
reset.
39
FEATURES
Instrumentation
MFD Digital Display Programs
Performance 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 seconds.
3. Press the MODE button to save the hour and flash the minutes.
4. Set the minutes in the same manner.
5. When finished, press the MODE button to save the new setting.
NOTE:
If the MODE button is not pressed within ten seconds, the
clock will automatically save the new entry.
Engine Program
The Engine Program automatically displays the engine coolant
temperature, engine hours, electrical system voltage level and fuel
level. On machines equipped with altimeter sensor and ambient air
temperature sensors, altitude and ambient air temperature will display
as additional screens in the engine program. Press the SET button to
display the ambient air temperature and altitude screens (if equipped).
On turbo-charged models, the boost pressure screen follows these two
screens.
Air Temperature (if equipped)
The MFD displays actual air temperature.
Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.
40
Instrumentation
FEATURES
MFD Digital Display Programs
Altitude (if equipped)
The rider can calibrate the altimeter for
current atmospheric conditions. Altimeter
accuracy will be +/-300 ft. (91 m) after
adjustment.
NOTE:
Press and hold the MODE switch
for ten seconds to switch
between standard and metric units of measurement. When
“ALt” displays, the program is in the metric mode.
1. Enter the Engine Program and select the altimeter display.
2. Press and hold the SET button for five seconds.
3. When the digits begin to flash, press the SET button once to
advance 50 feet (15 m), or press and hold the button to advance
100 ft. (30 m) every 0.1 seconds. Adjust the altitude display to
within 50 ft. (15 m) of current altitude.
NOTE:
The gauge reads barometric pressure and allows the rider to
compensate for daily fluctuations in air pressure. The gauge
can adjust the displayed altitude to +/- 1300 ft. (396 m) from
the preset value. It will adjust up to +1300 ft. (396 m) above
the calibrated altitude. Once the +1300 ft. (396 m) offset has
been reached, the next adjustment is -1300 ft. (396 m) from
the calibrated altitude, and 50 ft. (15 m) will be added to the
altitude each time the SET button is pressed.
4. Press the MODE button to hold the reading at the adjusted value. If
it’s not pressed within five seconds, the gauge will automatically
save the new setting.
Hour Meter
The hour meter records the total hours of
engine operation since manufacture. This
meter cannot be reset.
Engine Temperature
A thermometer measures water temperature,
giving an indication of engine temperature.
41
FEATURES
Instrumentation
MFD Digital Display Programs
History Program
The History Program automatically displays electrical system voltage
level and fuel level.
While in the History mode, press the SET button to view maximum
vehicle speed, maximum engine rpm or the current service interval
setting. The gauge automatically logs the maximum speed and engine
rpm even if the History Program is not currently displayed.
The History Program will display the history of the Maximum Speed,
Maximum RPM and Service Interval settings.
Maximum Speed/RPM Reset
While in either the MAX MPH or the
MAX RPM mode, press and hold the
SET button for three seconds to reset
the recorded maximum values for both
MPH and RPM. Both of these values
are reset at the same time. Reset the
MAX MPH/RPM values before each
run to obtain accurate readings.
NOTE:
42
Due to electrical noise, the
MFD may occasionally
display MAX MPH/RPM
values that are not
representative of actual
values.
Instrumentation
FEATURES
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 gauge provides a reminder
that service is due. “SErVCE” will
flash in the odometer area and “ENG”
will flash in the icon area for five
seconds each time the vehicle is
started until the service reminder is reset.
See the maintenance charts beginning on page 88 for recommended
service intervals.
To reset the reminder at the existing interval:
1. Enter the service interval screen.
2. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.
3. When the display stops flashing, release the button. The service
interval has been reset.
To reset the reminder at a new interval:
1. Enter the service interval screen.
2. Press and hold the SET button for five seconds, until the hours
begin to flash.
3. Immediately release the button.
4. Press the button again up to five times to advance the reminder in
50-hour increments.
NOTE:
The maximum interval is 250 hours.
To disable the service interval reminder, press the SET button once
after reaching 250 hours on the display. The gauge will display
“OFF”.
43
FEATURES
Instrumentation
MFD Battery Replacement
If the clock function of the MFD isn’t
A
working properly, replace the battery.
Replacement batteries are available
from your dealer.
1. Remove the plenum from the
underside of the hood.
2. Locate the black battery
B
compartment (A). It has a red
wire and a brown wire with a
white stripe. It’s located about
three inches down the main
harness from the point where the
harness connects to the MFD.
3. Cut the plastic cable tie (B) from
C
the outside of the compartment.
4. Carefully cut the bottom of the
compartment (opposite the wires)
to separate the heat-sealed seams.
Squeeze the corners of the compartment inward so the battery (C)
is visible.
NOTE:
Note the orientation of the battery before removing it. An
incorrectly installed battery will not maintain the clock.
5. Using needle-nose pliers, grasp the battery and rotate it slightly so
the leading edge of the battery is raised slightly away from the
battery holder. Pull the battery out gently.
NOTE:
44
The battery will not come out of the holder unless the leading
edge of the battery is raised. Hold the battery compartment,
not the wires, while removing the battery. Pulling on the
wires will separate them from the battery holder.
Instrumentation
FEATURES
MFD Battery Replacement
6. Install a new battery with fingers only.
7. Seal the end of the battery compartment using high strength
double-sided tape between the two compartment halves or high
strength single-sided tape around the outside of the compartment.
8. Make sure the taped seam of the compartment faces the downward
side of the wire harness.
9. Install a cable tie to secure the compartment to the wire harness in
the same location where the previous cable tie was located. Make
sure the battery wires are not stretched tight.
Gauge Cleaning
1. Wipe the gauge face as needed using a clean cloth and a mild soap
and water solution. Wipe dry with clean, soft cloth.
2. Clean the back side of the gauge using a clean cloth and a mild
soap and water solution. Do not remove the electrical connectors
or protective rubber boot. Do not spray the back side of the gauge
or the wire harness with a pressure washer or other water source.
CAUTION
To prevent damage to the lens, do not use alcohol for cleaning.
Do not allow chemicals or sprays to come into contact with the
lens. Immediately clean off any gasoline that splashes on the
gauge during refueling.
45
THE PERFECT FIT
IQ Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for approximately 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 conditions. We recommend
starting with factory settings and then customizing each adjustment
individually to suit rider preference. The snowmobile should be
methodically tested, one change at a time, under the same conditions
(trail and snow conditions, vehicle speed, riding position, etc.) after
each adjustment until the best ride is achieved.
IFS Components
1. Skis
2. Front shocks and springs
3. Rod ends
4. A-arms
2
1
3
IFS Adjustment Options
S Shock damping (if equipped
with ArvinMeritor MPV
Select shocks)
S Front shock spring preload
S Optional springs
S Optional shock valving
(Switchback)
S Toe (ski alignment) (see page 126)
S Camber (see your dealer)
46
4
THE PERFECT FIT
IQ Front Suspension Adjustments
Shock Damping
Adjustments to the compression stiffness
+
of ArvinMeritor MPV Select shocks
can be made by turning the adjustment
screw (+) located near the base of the
shock. This adjustment is the easiest to
perform and it should be considered
first.
The factory setting for this shock is the
softest position, with the adjusting screw
all the way out (counterclockwise). If
bottoming occurs, turn the screw
clockwise to increase compression and
stiffen the ride.
When adjusting these shocks, we recommend that you turn the screw
only 1/4 turn at a time, then test ride. Always adjust both shocks
equally.
Front Shock Spring Preload
The factory preload setting should be appropriate for most riders and
conditions. Please see your Polaris dealer for assistance before
attempting to adjust preload.
Increasing the spring preload too much may adversely affect the
handling of the snowmobile and the performance of the rear
suspension.
Decreasing the spring preload too much may allow the upper spring
retainer to fall off.
47
THE PERFECT FIT
IQ Front Suspension Adjustments
Shock Valving (Switchback)
The shocks can be revalved if spring preload alone isn’t sufficient and
further adjustment is desired to control suspension stiffness.
WARNING
Changing shock valving requires special tools and a sound
knowledge of mechanical theory, tool use, and shop procedures
to perform the work safely and correctly. Shocks contain
high-pressure nitrogen gas. Use extreme caution when handling
high-pressure service equipment. We recommend that this work
be performed by a Polaris dealer.
Front Springs
The front springs can be changed if spring preload alone isn’t sufficient
and further adjustment is desired to control suspension stiffness. See
your Polaris dealer for more information.
48
THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and
deliver excellent performance for a given set of conditions. However,
all suspension designs and adjustments involve a compromise, or
trade-off. For example, a suspension set up for snow-cross racing
would provide a very stiff ride on the trail. A suspension set up for
trail riding would bottom out harshly on a snow-cross course.
Make adjustments to one area at a time so you can evaluate the change.
For further assistance, see your dealer.
Suspension Performance Tips
S Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With
a little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
S In deep snow, a new rail slide will offer improved performance over
a worn slide. It can also improve top speed.
S Polaris offers track kits for improved flotation in deep snow. See
your dealer for assistance.
NOTE:
Keep the suspension pivot points lubricated. This will reduce
moisture and rust build-up and ensure proper function of the
suspension components. Grease rear suspension pivots
before adjusting the rear suspension. Refer to Suspension
Maintenance beginning on page 98.
49
THE PERFECT FIT
Switchback Rear Suspension
Initial Spring Preload Setting (Sag Method)
To set up the rear suspension
torsion spring preload, measure
the distance between the ground
and rear bumper. This is
measurement X.
Take this measurement with no
rider and with the rear suspension
at full extension.
NOTE:
The rear bumper may
need to be lifted
upward slightly to fully
extend the suspension.
Next, have the rider drop down
hard on the seat and bounce up
and down several times,
collapsing the rear suspension.
With the rider seated, measure the
distance between the ground and
the rear bumper at the exact
location used for measurement X.
This is measurement Y.
To determine sag, commonly referred to as ride-in, subtract
measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion
spring preload cams located on the rear torque arm. See illustration.
The ideal amount of sag for this rear suspension is five inches (12.7
cm) (X-Y=5 in./12.7 cm).
If the rear suspension rides in less than four inches or more than six
inches with the torsion spring preload cams at their maximum range of
adjustment, optional torsion springs (softer or stiffer, respectively) may
be required. This is only an initial setup, and final spring preload may
vary based on rider preference and riding conditions.
50
THE PERFECT FIT
Switchback Rear Suspension
Rear Torsion Spring Tension
To adjust rear torsion spring tension, rotate the three-position cam
using the engine spark plug tool.
Different rate torsion springs are available if a firmer ride is desired.
Contact your dealer for more information.
C
A
B
A. Soft Tension - long end of cam to front
B. Medium tension - short end of cam up
C. Firm tension - long end of cam up
Limiter Strap Position
The following information is
provided only as a guideline to be
used for initial suspension set-up.
Your set-up may vary based on your
desired riding style.
A. Limiter strap in high position
increases ski pressure
B. Limiter strap in low position
decreases ski pressure
A
B
51
THE PERFECT FIT
Switchback Rear Suspension
Rear Track Shock Compression Damping
A. Turn rear track shock screw clockwise to stiffen compression.
B. Turn the rear track shock knob clockwise for a softer ride.
C. Turn the rear track shock knob counter clockwise for a stiffer ride.
B
A
52
C
THE PERFECT FIT
Switchback Rear Suspension
Rear Shocks
When adjusting, we recommend that you turn the adjuster slightly,
then test ride. The recommended setting for this shock is eight (8)
clicks counter-clockwise.
FOX Zero Pro XC Shock
The FOX Zero Pro XC shock is standard on the Switchback model.
Turn the adjustment knob (L) on the shock reservoir to make
adjustments to the compression damping.
L
53
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
The M-10 suspension has been designed to be very sensitive to rider
weight. Changes in rider weight of 25 lbs. (11 kg) or more might
require appropriate changes in settings. The following information has
been compiled to assist you in tuning your M-10 suspension to its
maximum potential and achieve the best possible ride. Please take the
time to read and understand all the possible adjustments available with
this suspension.
Static Sag and Ride Height Settings
Static sag describes the difference in height of the rear bumper from the
suspension’s fully extended position to its loaded height, with the rider
seated on the snowmobile. Too much sag will result in bottoming, and
too little sag will result in reduced rider comfort.
Sag is used to control ride quality and rebound travel. On this
suspension, sag is controlled by two settings, the full range adjuster
(FRA) position and the rear spring preload.
1. To check sag, raise the rear bumper until the suspension is fully
extended (the rear shock will not extend any further). Measure the
distance from the ground to the bottom of the bumper (dimension
X) as shown in the illustration. Record the measurement.
2. Have the rider sit on the snowmobile and bounce up and down on
the seat a few times to set in the suspension. While the rider
remains seated, measure the distance from the ground to the top of
the bumper (dimension Y) and record it.
54
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
3. Subtract Y from X and you will have the SAG setting (X - Y = sag
setting. Example: 21 - 17 = 4). The correct amount of SAG for
the FAST M-10 rear suspension is 3-4 inches (8-10 cm).
If the measured sag is incorrect, adjust the FRA position and rear
spring preload. See pages 56--57.
X
Y
55
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
FRA Position
The FRA setting is the primary rear suspension adjustment. It will have
the MOST effect on the rear suspension performance. To adjust the
FRA:
1. Refer to the initial set-up reference chart (located under the hood of
your snowmobile or on page 59) to determine the desired FRA
position.
2. To adjust, loosen the hex bolts (A) attaching the rear lower shock
cross shaft to the rail beam.
3. Using a 9/16” wrench, loosen the jam nuts (B) on the preload
bolts.
4. Adjust the preload bolts (C) to the desired FRA position.
5. Tighten the jam nuts.
NOTE:
Make sure the preload bolt contacts the slide block before
tightening the jam nut.
6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).
NOTE:
When the M-10 suspension is new, it will take from 25 to 200
miles (40-300 km)to properly break in the springs and
shocks, at which time the suspension will be softer and may
require FRA re-adjustment.
A
56
B
C
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
Rear Spring Preload
If FRA position alone does not allow the setup of the proper amount of
sag, the center retainer of the rear track shock can be replaced with
optional retainers to adjust the preload and change the sag. See your
Polaris dealer for assistance.
OPTIONAL RETAINERS
Retainer Insert
Part Number
Retainer Part
Number
Preload
Sag
Least
Most
5436109
5135077
(standard on
M10-128)
5134923
Middle
Middle
5135080
(standard on
M10-136)
Most
Least
NOTE:
Whenever ordering any of the retainers listed in the chart,
always order the retainer insert as well. The insert is not
removeable once installed, so a new insert is needed when
installing a new retainer.
57
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
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 strap and front arm mount.
4
1. Determine if the rider
prefers comfort or
3
control. Lean toward the
#4 setting for comfort
2
and toward the #3
1
setting for aggressive
riding.
2. For full hole
2
adjustments,
3
remove the 5/16”
4
nut and flat washers
from the lower
attachments of the
limiter straps and relocate
the straps to the desired position
(i.e. move from position 4 to 3). Replace the nut and washer.
Tighten securely.
3. For half-hole increments (such as 3/4), the limiter straps have slots
at the upper pinch bolt. These slots allow the bolts to be loosened
(rather than removed) for half--step adjustments. Re--tighten the
pinch bolts.
58
THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
Ski Pressure
4. There are also two
front arm mounting
holes in the slide rail
that can adjust ski
pressure. The lower
hole (A) increases ski
pressure while the upper
hole (B) decreases ski pressure.
NOTE:
B
A
By design, the BIASED COUPLE design of the M-10
suspension displaces the rear arm as the front arm is
compressed. This means that when you raise the front
limiter strap, at some point you will collapse the rear
suspension arm, which will affect SAG height and reduce
rear suspension travel.
Initial M-10 Suspension Set-up Charts
These charts are a guideline to be used for initial suspension set-ups.
Your set-up may vary based on your desired riding style.
M10-128
M10-136
Rider Weight
with Gear
(lbs.)
Suggested FRA
Range (Lower
Number is Softer)
Rider(s)
Weight with
Gear (lbs.)
Suggested FRA
Range (Lower
Number is Softer)
Under 100
1 to 1 1/2
Under 100*
1 to 1 1/2
100-150
1 1/2 to 2
100-150*
1 1/2 to 2
150-200
2 to 2 1/2
150-200*
2 to 2 1/2
200-250
2 1/2 to 3
200-250
2 1/2 to 3
250-300
3 to 3 1/2
250-300
3 to 3 1/2
300-350*
3 1/2 to 4
300-350
3 1/2 to 4
350+*
4 to 5
350+
4 to 5
*You may prefer an optional rear track middle spring retainer. See page 57.
59
THE PERFECT FIT
Handlebar Adjustments
Use the RIDER SELECT feature to adjust handlebar position. See
page 31. Use the following steps to adjust handlebar angle at the
handlebar block.
C
1. Remove the handlebar cover (A)
to expose the handlebar and the
four adjuster block bolts (B).
NOTE:
If equipped, remove the
mountain bar (C).
2. Using a 7/16″ (11 mm) wrench,
loosen the four nuts (D) on the
bottom of the adjuster block (turn
handlebar to left or right for
access to back nuts).
NOTE:
If necessary, pry the
blocks apart with a
screwdriver.
A
B
D
3. Adjust the handlebar to the desired height. Be sure handlebars,
brake lever and throttle lever operate smoothly and do not hit the
gas tank, windshield or any other part of the machine when turned
fully to the left or right.
4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-18
Nm).
NOTE:
Torque the front bolts first.
5. Reinstall the handlebar cover.
60
THE PERFECT FIT
Passenger Grab Handle Adjustment (Touring)
On some Touring models the position of the
passenger grab handles can be adjusted for
rider preference. To make an adjustment:
1. Unscrew and remove the knob
assemblies (A) that secure the grab
handles.
2. Reposition the grab handles to one of the
three available positions on the grab
handle tube between the operator seat
and the passenger seat.
3. Reinstall the knob assemblies and
tighten securely.
A
Accessories
Polaris offers a wide range of accessories 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:
S Non-compliance with government/industry requirements
S Voiding of warranty
S Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems.
NOTE:
Exhaust systems are critical safety areas that must use
approved Polaris parts. Please see your Polaris dealer for
service.
61
THE PERFECT FIT
Traction Products
Studs
Before equipping your snowmobile with traction products, be aware of
the laws in your area pertaining to the use of traction products.
Use only Polaris traction products on your snowmobile. Track
warranties are void if track damage or failure results from improper or
excessive stud installation or the use of non-Polaris traction products.
See your dealer about installing studs and/or carbides.
CAUTION
Always install wear strips before installing studs. Failure to install
wear strips may result in cooler or tunnel damage. See page 63.
Never add shims to the wear strip. Track damage will result
because of lack of clearance between upper carrier wheels and
track.
Use of studs longer than the recommended length on machines
equipped with center coolers will result in center cooler damage
or damage to the tunnel.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering
ability may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are
available. See your dealer.
CAUTION
Aggressive studding patterns may require grinding protruding
stud bolts flush to prevent idler wheel damage. Maintain track
tension on studded tracks on the tight side of the spec to prevent
heat exchanger damage. Center of stud must be at least 1 1/8″
(2.86 cm) from the outside edge of the track.
62
Traction Products
n Carbide Skags
THE PERFECT FIT
A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. Use carbide skags with studded
tracks to help maintain proper vehicle steering and control. See page
127.
If your snowmobile has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags
(the more studs you use, the longer the carbide on the skags should be).
See your dealer’s track studding chart.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used.
Install the appropriate wear strip kit. See your dealer.
Wear strips are designed for a specific stud length. See your dealer’s
studding chart for recommended traction accessories.
CAUTION
Whenever wear strips are relocated, be sure there’s adequate
stud clearance to the heat exchangers. Lack of clearance may
result in damage to heat exchangers.
63
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the
referenced pages. Look for a checkmark (n) on the referenced pages
to locate the pre-ride inspection items.
Item
Drive Belt Condition
Steering System
Park Brake Lock/Brake Lever/Brake System
Throttle Lever
Throttle Safety Switch
See Page
117, 117
66
67, 68, 111
65, 81
65, 80, 83
Auxiliary Shut-Off Switch (Engine Stop Switch)
71, 83
Ignition Switch
71, 83
Taillight/Brakelight/Headlight
71
Coolant Level
106
Gearcase Oil Level
100
Engine Oil Level
92
Foam Oil Breather Element
97
Suspension Mounting Bolts
Skags (Wear Bars)
70
63, 127
Ski Saddle and Spindle Bolts
70
Hood Straps/Latches
66
Seat Latches
65
Rear Wheel Idler Bolts
123, 70
Track Alignment/Condition
69, 124
Rail Slide Condition
124
Oil Level (check before operating if vehicle was tipped over)
72
64
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
WARNING
Worn, damaged, or malfunctioning components may cause
serious injury or death. Before starting the engine, check all
components to be sure of proper operation.
Read and Understand Your Owner’s Manual
Read the Owner’s Manual completely and refer to it often. The manual
is your guide to safe and enjoyable snowmobiling experience.
n Throttle Lever
The throttle and brake are the primary controls of your snowmobile.
Always make sure both are functioning properly.
Squeeze the throttle lever to make sure it compresses evenly and
smoothly. When released, the lever should immediately return to the
idle position without binding or hesitation. If the throttle does not
function smoothly, or if you discover excessive lever freeplay, DO
NOT start the engine. Have the throttle serviced immediately.
n Throttle Safety Switch
Test the throttle safety switch system before the snowmobile is
operated. See page 80 for procedure.
n Seat Latches
Ensure that the seat latches are securely in place before every use of the
snowmobile.
65
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
n Hood Latches
The hood of the snowmobile protects the operator from moving parts
as well as aiding in sound emission control and other functions. Under
no circumstances should your snowmobile be operated with the hood
open or removed. Always ensure that the hood straps are in good
condition and that the latches are securely in place before operating the
snowmobile.
n Steering System
WARNING
Ice and snow build-up may interfere with the steering of your
snowmobile, resulting in serious injury or death. Keep the
underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure
ice and snow are not interfering with full left and right steering. If
difficulty is encountered, remove ice and snow build-up that may be
obstructing the steering linkage.
NOTE:
66
If your snowmobile is equipped with RIDER SELECT,
perform this check in both the full up and full down steering
positions.
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
n Brakes
Always check the
following items for proper
operation before starting
the engine.
1/2″
(1.3 cm)
Brake Lever Travel
Squeeze the brake lever.
It should move no closer
to the handgrip than 1/2″ (1.3 cm).
A smaller distance indicates low brake fluid level or air in the
hydraulic system. Refer to the brake bleeding information on page 113.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 112.
Check for the presence of air in the fluid system. See page 113 for more
information, or see your dealer for service.
WARNING
Continued use of “spongy” brakes may cause a complete loss of
brakes, which could result in serious injury or death. Always have
the brakes serviced at the first sign of sponginess.
67
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
n Park Brake Lever Lock
Use the park brake lever lock only when you want the snowmobile to
remain stationary; for example, when parked on an incline for a period
of five minutes or less.
A. Brake Lever
C
B
D
B. Park Brake Lever Lock
A
C. Master Cylinder
Reservoir / Cover
D. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze the
brake lever tightly and push
forward on the lock. Hold the
lock forward while releasing the
brake lever.
NOTE:
If the brake lever is squeezed tightly enough, the lock will
move freely into place. Do not force the lock or it may break.
The park brake light on the gauge, will light up if the park brake lever
lock is set while the engine is running. It will also be lit when the
service brake is in use. If the park brake light does not come on when
the park brake or service brake is in use, have it serviced by your
dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will
return to the unlock position.
WARNING
If the park brake lever lock is partially or entirely engaged while
riding, the brakes may overheat, resulting in brake damage. In
extreme cases it could cause a fire, which could result in serious
injury or death. Always ensure that the lever lock is completely
disengaged before operating the snowmobile.
68
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
n Track Inspection
WARNING
Operating the snowmobile with a damaged track increases the
possibility of track failure, which could cause loss of control
resulting in serious injury or death. Always inspect the track for
damage before using the vehicle.
Use of traction products such as studs increases the possibility of track
damage and/or failure. Driving at high speeds for extended periods of
time in marginal lubrication could severely damage track rods, break
track edges and cause other track damage. Examples of marginal
lubrication would include frozen bodies of water without snow cover,
icy trails, and no-snow conditions.
NOTE:
Track damage or failure caused by operation on ice or poor
lubrication conditions voids the track warranty.
69
PRE-RIDE INSPECTIONS
Check Before Starting the Engine
n Suspension Inspection
Loose nuts and bolts can reduce your snowmobile’s reliability and
cause needless repairs and down time. Before beginning any
snowmobile trip, a visual inspection will uncover potential problems.
Check the following items on a weekly basis or before any long trip.
Item
Check
Page
Suspension mounting bolts
Tightness
--
Rear idler wheel bolts
Tightness
123
Rear idler adjusting bolt locknuts
Tightness
--
Torque arm bolts
Tightness
--
Carrier and bogie wheel bolts
Tightness
--
Front torque arm limiter strap
Condition
--
Rail slide
Condition
124
Track
Tension
122
Lubrication
98
Ski runner/skag
Condition
--
Ski spindle bolts
Tightness
--
Tie rod end nuts
Tightness
--
All rear suspension components
70
PRE-RIDE INSPECTIONS
Check After Starting the Engine
n Engine Stop Switch
Check the auxiliary shut-off switch for proper operation. Push the
switch down to stop the engine. Pull it up to allow restarting.
n Ignition Switch
Make sure the engine stops when the ignition switch is turned to OFF.
n Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
n Mirror Adjustment
If equipped, adjust your mirrors so they can be used to their full
advantage.
n Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the snowmobile.
71
PRE-RIDE INSPECTIONS
n Tip-Over Inspections
In the event of a tip-over or rollover, check the oil level before
operating the snowmobile.
CAUTION
Failure to check the oil after a tip-over can result in serious
engine damage. Always check the oil level before operating a
snowmobile that has tipped over or rolled over.
NOTE:
In the event of a tip-over or rollover, the engine will stop. To
restart the engine, turn the key to the OFF position, then
restart.
WARNING
Operating a snowmobile with accident damage can result in
serious injury or death. Do not operate the snowmobile if vehicle
components have been damaged in a collision or tip-over. Have
the snowmobile inspected by an authorized Polaris dealer.
72
Fuel Safety
OPERATION
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel outdoors or in a well-ventilated area.
S Always turn off the engine before refueling.
S Do not overfill the tank. Do not fill the tank neck.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area. Engine
exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
73
OPERATION
Break-In Period
The break-in period for your new Polaris snowmobile is the first 500
miles (800 km) of operation. No single action on your part is as
important as following the procedures for a proper break-in. Careful
treatment of a new engine and drive components will result in more
efficient performance and longer life for these components.
CAUTION
Excessive heat build-up during the first 500 miles (800 km) of
operation will damage close-fitting engine parts. Do not operate at
full throttle or high speeds for extended periods during the
break-in period.
Use of non-recommended oil may cause serious engine damage.
Always use the recommended oil for your Polaris snowmobile.
1. Fill the fuel tank with the recommended fuel. See page 79.
2. Check the oil level in the oil tank. See page 92. Add oil if
necessary to maintain at the recommended level.
3. Drive slowly at first. Vary the throttle positions. Do not operate at
sustained idle.
4. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 64.
5. During the break-in period, change both the oil and the filter at 500
miles or before seasonal storage, whichever comes first.
74
Starting the Engine
OPERATION
WARNING
Before starting the engine, always refer to all safety warnings
pertaining to snowmobile operation. Never start your snowmobile
without checking all components to be sure of proper operation.
See Check Before Starting the Engine beginning on page 65.
Do not depress the throttle until the engine starts.
1. Turn the key to the ON position.
2. Pull the engine stop switch up to the RUN position.
CAUTION
To avoid injury and/or engine damage, do not operate the electric
starter while the engine is running.
3. Turn the key to START to crank the engine. Release the key to the
ON position when the engine starts.
4. Repeat the cranking procedure as needed until the engine starts.
75
OPERATION
Emergency Starting
If the battery is too weak to start the engine, and a battery charger is
not available, the engine can be started using jumper cables and a
charged battery from another vehicle. Carefully read and follow the
instructions below.
WARNING
Improperly connecting or disconnecting jumper cables can result
in an explosion and cause serious injury or death. When
connecting jumper cables, always connect the negative (usually
black) cable last. When removing jumper cables, always
disconnect the negative (usually black) cable first.
WARNING
Loose-fitting clothing can get caught in the engine when the
vehicle is running with the hood open. This can cause serious
injury or death. Remove or control all items that could catch in
the engine, including scarves, gloves, jackets and clothing straps
and hooks.
NOTE:
If a car or truck battery will be used to jump start the
snowmobile, turn the engine off. A running engine will put
out too much electrical current for the snowmobile battery.
NOTE:
Never attempt to jump start a discharged battery that is
frozen.
1.
2.
3.
4.
Always wear eye protection when jump starting your vehicle.
Keep bystanders away from the vehicles.
Perform the emergency starting procedure in a well-ventilated area.
Position the vehicles close enough for the jumper cables to reach
easily between the batteries, but do not allow the vehicles to touch
each other.
5. Lock the parking brakes on both vehicles to prevent accidental
movement.
6. Open the hood and remove the left side panel.
7. Decide which of the jumper cables will be positive (usually red or
yellow) and which will be negative (usually black).
NOTE:
76
Never connect a jumper cable to the fuel system or fuel lines.
Emergency Starting
OPERATION
8. Pull back the red plastic boot covering the positive terminal of the
weak battery. Connect one end of the positive jumper cable to the
positive terminal of the weak battery.
9. Connect the other end of the positive jumper cable to the positive
terminal of the charged battery.
NOTE:
Make sure that the end of the negative cable by the weak
battery is not contacting the snowmobile battery or chassis.
10. Connect the other negative end of the jumper cable to the negative
terminal of the charged battery.
11. Connect the end of the negative jumper cable by the weak battery
to the CHASSIS of the snowmobile. There may be a small spark
when this is done, but this is normal.
NOTE:
Always be sure that the jumper cables do not interfere with
the belts, pulleys or clutches on either vehicle.
12. Make sure that the engine stop switch is in the UP position.
13. Attempt to start the vehicle.
14. If the engine does not turn over (crank over), wait 30 to 60 seconds
and attempt to start the engine again. If the engine does not start,
wait another 1 to 2 minutes and attempt to start the engine again.
15. If the engine still does not start, try adjusting the clips on the
jumper cable ends to ensure that they have a good electrical
connections. Repeat step 14.
16. If the engine still does not start, remove the jumper cables as
outlined in step 17 and transport the snowmobile to an authorized
Polaris dealer for service.
17. Carefully remove the jumper cables in this order:
A. Remove the negative end of the jumper cable from the
snowmobile chassis.
B. Remove the negative end of the jumper cable from the
charged battery.
C. Remove the positive end of the jumper cable from the
charged battery.
D. Remove the positive end of the jumper cable from the weak
battery.
18. Reinstall the left side panel.
19. Close and secure the hood.
77
OPERATION
Track Warm-Up
WARNING
A loose track or flying debris could cause serious injury or death.
Stand clear of the front of the machine and the moving track.
Never hold the snowmobile up or stand behind it while warming
up the track. Do not use excessive throttle during warm-up or
when the track is free-hanging. Be sure the rear support is
stable.
WARNING
Use of traction products such as studs, ice growsers, etc. will
increase the possibility of track damage and/or failure. This could
cause loss of control, resulting in serious injury or death. Always
inspect for track damage before operating the snowmobile.
Follow these steps to ensure
proper warm-up of the engine,
drive train and track.
1. Use an appropriate stand to
securely support the rear of
the snowmobile at the rear
bumper. The track should be
approximately 4″ (10 cm) off
the ground.
2. Start the engine and allow it
to warm up two to three
minutes.
3. Depress the throttle abruptly and allow the track to rotate several
revolutions.
NOTE:
It will take longer to warm up the track sufficiently during
colder outdoor temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the snowmobile to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
78
Fuel
OPERATION
For peak performance, 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 use
fuel lower than 87 octane.
CAUTION
Operating with obstructed fuel systems will result in serious
engine damage. Perform maintenance as recommended.
Damage to the fuel pump will occur if the snowmobile is operated
with an empty fuel tank. Do not allow the snowmobile to run out
of fuel. Always refuel when the level is low.
Prolonged exposure to petroleum based products may damage
paint. Always protect painted surfaces when handling fuel.
Fuel Level
The fuel symbol and the last fuel bar on the MFD gauge will blink
when the fuel level reaches 1/8th tank. There will be approximately
one gallon of fuel remaining. Refuel as soon as possible. Do not allow
the snowmobile to run out of fuel.
Fuel System Deicers
If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or
additives containing methanol. Polaris also recommends the use of
Carbon Clean Plus. See page 133 for the part numbers of Polaris
products.
If you use oxygenated fuel containing ethanol, additional alcohol
deicers or water absorbing additives should not be used.
79
OPERATION
n Engine Stop Switch
L
Push down on the engine stop
switch (L) to ground out the
ignition and stop the engine
quickly. Pull the switch up to the
RUN position to allow restarting.
n Throttle Safety Switch
The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.
WARNING
Operating the snowmobile with a faulty throttle safety switch can
result in serious injury or death in the event of an accident. If the
throttle safety switch does not shut off the engine during a throttle
system malfunction, immediately push down the engine stop
switch. Do not start the engine again until the malfunction has
been corrected by your dealer.
Test the throttle safety switch
L
system daily before operation.
1. Sit on the seat.
2. Start the engine and allow it to
idle.
3. Hold the throttle lever pin
stationary by exerting pressure
on the pivot pin in the direction
shown in the illustration (L).
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
80
n Throttle Lever
OPERATION
WARNING
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 start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and throttle body to determine
what caused the safety switch to activate.
3. Test the throttle lever by compressing and releasing it several
times. The lever and cable must return to the idle position quickly
and completely.
4. If the throttle lever operates properly, turn the ignition switch on
and go through normal starting procedures.
5. If the engine doesn’t start, take the snowmobile to an authorized
Polaris dealer for service.
NOTE:
Excessive freeplay in the throttle cable may cause the safety
switch to activate, preventing the engine from starting. If this
occurs, return the snowmobile to an authorized Polaris
dealer for service.
If an emergency exists and it’s necessary to start the engine, the throttle
safety switch and engine stop switch may be disconnected from the
wire harness. When these switches are disconnected, the ignition key
switch must be used to shut off the engine. DO NOT continue to
operate the snowmobile with the throttle safety switch disconnected.
Return the snowmobile to an authorized Polaris dealer for service as
soon as possible.
Turbo Noise (FST)
Under some conditions, when the throttle lever is released the boost
pressure dump valve will release pressure, and you may hear the sound
of escaping air. This is a normal occurrence on turbo-charged models.
81
OPERATION
Electronic Reverse (PERC 4t)
Electronic reverse will activate only when the vehicle is stopped and
engine speed is below 2500 RPM. Maximum engine speed when
operating in reverse will be 6000 RPM.
WARNING
Improper reverse operation, even at low speeds, may cause loss
of control, resulting in serious injury or death. Damage will occur
to the gearcase or transmission if shifting is attempted when the
engine is operating above idle speed.
S Shift to or from reverse only when the snowmobile is stopped
and when engine speed is at idle.
S Look behind the snowmobile before and while backing.
S Avoid sharp turns.
S Apply throttle slowly.
Engaging Reverse
1. Stop the snowmobile and leave the
engine idling.
2. Make sure the area behind your
snowmobile is clear.
3. Push the yellow reverse button on the
left-hand control for one second, then
release.
NOTE:
L
A reverse light on the instrument panel will indicate that the
snowmobile is in reverse.
4. Apply the throttle slowly to make sure the snowmobile is in
reverse.
NOTE:
If the engine stops running, the snowmobile will be in forward
gear when it’s restarted.
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Push the yellow reverse button for one second and release. The
light on the instrument panel will shut off.
3. Apply the throttle slowly to make sure the snowmobile is in
forward.
82
n Emergency Stopping
OPERATION
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 80 for more information about the
engine stop switch and throttle safety switch.
SYSTEM
WHAT IT DOES
THROTTLE
CONDITION
Ignition Switch
Interrupts ignition circuit
All
Brake
Slows jackshaft
All
Engine Stop Switch
Interrupts ignition circuit
All
Throttle Safety Switch
Interrupts ignition circuit
All
83
OPERATION
Daily Storage
At the end of each ride, park the
snowmobile on a level surface
and support it at the rear with an
appropriate track stand. The
track should be suspended
approximately 4″ (10 cm) off
the ground.
Remove the key and cover the
snowmobile.
Towing
WARNING
Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting
in serious injury or death. DO NOT tow toboggans, sleds,
saucers, or any type of vehicle with a rope. Only a stiff metal
pole connecting the towed object and the tow hitch on the
snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2
meters) long to prevent any possibility of contact between the
snowmobile’s track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to
maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it
isn’t possible to use a rigid tow bar, attach the tow rope to the ski
spindles (not to the ski loops) to prevent damage to the steering
components. Remove the drive belt before towing, and have someone
ride on the towed snowmobile to operate the brake and steering when
necessary.
CAUTION
Towing a disabled snowmobile with the drive belt in place can
result in serious damage to the engine and drive system. Always
remove the drive belt from a disabled snowmobile before towing.
84
Emission Control Information
MAINTENANCE
Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission
control information (ECI) label and a factory-installed emissions
information hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. The emission control system designation
per SAE J1930 is MFI. If your snowmobile is equipped with a check
engine light and it comes on, you must take your snowmobile to a
qualified dealer for diagnostic service. Specifications and adjustments
for engine tune-ups are located in the Service Manual, which is
available to your qualified service technician. Reverse (if equipped)
must not be engaged during engine tune-ups.
85
MAINTENANCE
Emission Control Information
Owner’s Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty on
page 147, and read the maintenance section of your owner’s manual.
You are responsible for ensuring that the specified maintenance is
performed, including the emission--related maintenance outlined in
these sections of the manual.
You must inspect the air intake system on your snowmobile prior to
each use (including the airbox foam filter and hood foam filters) and
clean these components as necessary. Polaris considers the specified
maintenance for the spark plugs, oil changes, air intake system and
exhaust valves to be critical emission--related maintenance. The
specified maintenance for the fuel filter is recommended additional
emission--related maintenance. Polaris recommends that you contact
an authorized Polaris dealer to perform any service that may be
necessary.
86
MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as
outlined in this manual. Record maintenance and service in the
Maintenance Log beginning on page 149.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1500 miles (2400 km). These inspections should be
performed by a qualified service technician. For continued optimum
performance and component life, continue maintenance checks at 1500
mile (2400 km) intervals.
All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the
registered owner. If, during the course of the warranty period, part
failures occur as a result of owner neglect in performing recommended
regular maintenance, the cost of repairs are the responsibility of the
owner.
Personal safety is critical when attempting to service or make
adjustments to your snowmobile. If you’re not familiar with safe
service or adjustment procedures and the use of tools, or if you don’t
feel comfortable performing these tasks yourself, contact an authorized
Polaris dealer for service.
NOTE:
Polaris does not recommend tipping the snowmobile onto it’s
side for service. Any time the snowmobile is tipped onto it’s
left side, always check the oil level and clean the foam oil
breather element. See page 97.
CAUTION
Hot components can cause damage to plastic. Always make
sure the exhaust system and engine have cooled before tipping
the snowmobile on its side for service or inspection.
Tool Kit
A tool kit is included with each snowmobile for emergency use.
Always keep the tool kit with the snowmobile.
87
MAINTENANCE
Periodic Maintenance Interval Table
DAILY
or
PRERIDE
D = Perform Service
" = Replace
Item
Pg
Instructions
(see referenced pages)
Engine Stop Switch
71
Ignition Switch
71
Throttle Safety
Switch
80
Taillight
71
Brakelight
71
Headlight
71
D
Skags (Wear Bars)
127 Inspect for wear or damage, replace
when worn
D
Test for proper
p p operation.
p
Do not
operate if switches fail,
fail see your
dealer for service.
Test for proper
p p operation,
p
, replace
p
bulbs as needed
D
D
-
Inspect for fluid leaks
D
Test for proper engagement and release, see your dealer for service
D
Brake Lever
67
Check lever travel and lever “feel”
D
Coolant
106 Inspect level, add as needed
D
Brake fluid
112
Inspect fluid level, add as needed
D
Hood Latches
66
Secure properly, replace if damaged
D
Seat Latches
65
Secure properly, replace if damaged
D
Rail Slide
124 Inspect for wear or damage, replace
when worn
D
Foam Oil Breather
Element
97
Front/Rear
Suspension and
Steering Fasteners
70
Front Limiter Strap
-
88
1500
(2400)
D
68
-
mi
(km)
D
Parking Brake
Alternator Belt
mi
(km)
150
500
(240) (800)
YEARLY
or EVERY
D
Fluid Leaks
Oil Lines
INITIALLY
Check pre-ride, clean or replace
with each oil change. Clean after tipping 3 times onto left side.
D
CHANGE EVERY 2 YEARS
D
D
D
Inspect for missing or loose bolts
and fasteners, tighten or replace as
needed
WEEKLY / BEFORE LONG TRIPS
Inspect for wear, damage and missing or loose fasteners, replace as
needed
WEEKLY / BEFORE LONG TRIPS
Inspect, replace if worn or damaged
104 Check tension and condition,
replace if worn or damaged
D
D
D
D
D
D
MAINTENANCE
Periodic Maintenance Interval Table
DAILY
or
PRERIDE
D = Perform
" = Replace
Item
INITIALLY
mi
(km)
150
500
(240) (800)
YEARLY
or EVERY
mi
(km)
Pg
Instructions
(see referenced pages)
Coolant Hoses
-
Inspect, replace if worn or damaged
D
D
D
Heat Exchangers
-
Inspect, replace if damaged
D
D
D
Throttle Lever
65
81
D
D
D
Fuel Lines
103 Inspect, replace if worn or damaged
D
D
D
Clean terminals, test voltage
D
D
D
Track Alignment
124 Verify alignment, adjust as needed
D
D
D
Track Tension
122 Verify tension, adjust as needed
D
D
D
D
D
D
Battery
Handlebars
-
Drive Chain
110
Rear Track Shock
(M-10)
-
Verify alignment, adjust as needed
Verify tension, adjust as needed
EVERY
Inspect covers and caps for wear or
damage, replace as needed
EVERY
Gearcase Oil
100 Check at 500 mi. (800 km), change
every 1000 mi. (1600 km)
Rear Suspension
98
Bearings
1500
(2400)
D
EVERY
1000 (1600)
D
D
131 Lubricate drive shaft and jackshaft
bearings
D
D
Throttle Cable
98
Lubricate
D
D
Clutches
116
Verify offset alignment, inspect for
wear, residue, loose bushings,
see your dealer for all service
D
D
Check tension and condition,
replace if worn or damaged
D
D
D
D
"
"
Lubricate pivot shafts
(more often in wet snow conditions)
Drive Belt
117
Air Filter
104 Inspect for oil and dirt, replace as
needed
Oil/Filter Change
94
Replace oil and filter
89
MAINTENANCE
Periodic Maintenance Interval Table
DAILY
or
PRERIDE
D = Perform
" = Replace
Item
Engine Mounts
Pg
Instructions
(see referenced pages)
-
Inspect, replace if worn or damaged
INITIALLY
mi
(km)
150
500
(240) (800)
YEARLY
or EVERY
mi
(km)
1500
(2400)
D
D
Spark Plugs
102 Inspect condition/gap, replace as
needed
D
D
Exhaust System
105 Check muffler and pipe condition,
replace damaged or missing components, clean plastic surfaces
D
D
-
Inspect for wear, damage and proper routing, replace as needed
D
D
Brake Pads/Disc
111
Inspect, replace if worn or damaged
D
D
Fuel Vent Lines
103 Inspect, replace if worn or damaged
D
D
Ski Toe
126 Verify alignment, see your dealer for
adjustments
D
D
D
D
D
EVERY
3000 (4800)
Hoses
Cooling Fins/
Shroud
-
Inspect and clean
Valve Lash
-
See your dealer.
FS Specifications
Intake: 0.08 - 0.15 mm
Exhaust: 0.15 - 0.20 mm
FST Specifications
Intake: 0.08 - 0.15 mm
Exhaust: 0.18 - 0.23 mm
Cooling System
107 Bleed the cooling system, inspect
for leaks and proper circulation
Fuel Filter
103 Inspect, replace as needed
EVERY
2000 (3200
EVERY
2000 (3200)
Suspension Shock
Oil
90
-
Classic/Switchback only, see your
dealer for inspection
EVERY
2000 (3200)
Engine Oil
MAINTENANCE
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Table beginning on page 88. Always change the
oil filter whenever changing oil. See page 133 for the part numbers of
Polaris products.
Performance Synthetic 4-Stroke (PS-4) Oil
Polaris recommends the use of Performance Synthetic 4-Stroke (PS-4)
0W50 oil for this engine. PS-4 has been specially formulated for use
in Polaris 4-cycle snowmobile engines. It’s a fully synthetic, high
performance, multi-viscosity oil designed to provide the ultimate in
lubrication performance and protection.
Oil may need to be changed more frequently if Polaris oil is not used.
Always use 0W50 oil. Follow the manufacturer’s recommendations for
ambient temperature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. Always use the recommended oil.
Never substitute or mix oil brands.
91
MAINTENANCE
Engine Oil
n Oil Level Check
NOTE:
Read the entire oil check procedure before checking the oil
level.
The oil level will rise as engine temperature increases. The oil level
will be lower when the engine is cold. To obtain a proper oil level
reading, the snowmobile must be on a level surface, and the engine
coolant temperature must be between 145 and 160 degrees F. (63-71
degrees C). Never add or remove oil if the engine coolant temperature
is not within the specified range.
NOTE:
Always check the oil level before operating a snowmobile
that has tipped over.
CAUTION
Severe engine damage may occur if procedures for checking the
oil level are not followed precisely. Always check the oil with the
snowmobile positioned on a level surface. Always check the oil
when the coolant temperature is within the specified range.
1. Position the vehicle on a level surface.
2. If the engine is cold, start the engine and allow it to idle until the
engine coolant temperature reaches the specified range. Proceed to
step 4.
3. If the engine has been running, stop the engine and verify that
coolant temperature is within the specified range for performing
the oil check. Allow the engine to cool if necessary. When the
coolant is within the specified range, restart the engine and allow it
to idle for no more than 20 seconds to circulate the oil back into
the tank.
4. Turn the engine off.
NOTE:
Check the oil level within
three minutes, before the
coolant temperature (and
oil level) begin to drop.
5. Remove the dipstick (L)
from the oil tank.
92
L
Engine Oil
n Oil Level Check
MAINTENANCE
6. Clean the dipstick with a clean shop towel and reinstall it, screwing
it in completely.
7. Remove the dipstick and view the oil level.
NOTE:
The oil level reading will be accurate for only one to three
minutes after turning off the engine. If the oil check isn’t
completed within three minutes, reinstall the dipstick. Restart
the engine and allow it to idle for no more than 20 seconds to
circulate the oil back into the tank.
A. Fill mark for oil changes (at specified coolant temperature)
B. Safe operating range
A
B
8. Maintain the oil level in the safe operating range (B), between the
upper and lower marks on the dipstick. If the level is low, add the
recommended oil in small increments, about 2 ounces (60 ml), and
recheck the level. If the level is high, remove 2 ounces (60 ml) and
recheck the level.
CAUTION
Do not overfill the oil tank. Engine damage may occur. Always
add oil in small increments and recheck the level to avoid
overfilling.
9. Recheck the oil level if oil was added or removed, making sure the
coolant temperature is within the specified range. If necessary,
continue adding or removing oil until the level is in the safe
operating range.
93
MAINTENANCE
Engine Oil
Oil Change
Always change the oil at the intervals outlined in the Periodic
Maintenance Table beginning on page 88. Clean the foam oil breather
element with each engine oil change. See page 97.
Always use the recommended oil. See page 91, or see your Polaris
dealer about oil change kits, which contain a new filter and the
recommended oil.
NOTE:
A special jumper harness is required for changing the oil on
this vehicle. Please see your Polaris dealer to purchase the
harness, which will allow you to use the ignition key to turn
over the engine without starting it. You may also need an
assistant to help with the oil change.
1. Position the vehicle on a level surface.
2. Make sure the engine coolant temperature is between 145 and 160
degrees F. (63-71 degrees C). If necessary, start the engine and
allow it to idle until the coolant temperature is within the specified
range.
3. Turn the engine off.
CAUTION
Hot oil and a hot exhaust system and engine can cause serious
burns. Do not allow hot oil or hot components to contact skin.
4. Open the hood and remove the left side panel.
NOTE:
Clamp orientation is critical to the proper operation of the
system. Be aware of clamp placement and orientation when
removing hose clamps. Always reinstall hose clamps in the
same location and position.
5. Remove the oil return hose from the oil tank. Have an assistant
place the end of the hose into a drain pan.
6. Disconnect the starter motor solenoid control switch harness.
7. Insert the female WHITE/RED plug into the male pin from the
starter motor solenoid.
8. Insert the BROWN male pin of the jumper harness into the starter
solenoid’s female port.
94
Engine Oil
MAINTENANCE
Oil Change
9. Open the handlebar cover. Locate the connector with the BROWN
and RED/WHITE wires. Connect the BROWN wire from the
jumper harness to the BROWN wire on the handlebar harness by
inserting the harness plug into the handlebar wiring harness
connector.
10. Open the fuse box and remove the 20A EFI fuse from the fuse
block.
11. Reinstall the left side panel.
12. Have an assistant use the ignition key to turn over the engine.
Crank the engine for 15 seconds.
13. Wait 30 seconds to allow the starter motor to cool down.
14. Repeat steps 12 and 13 four more times for a total of five cycles.
15. Reconnect the oil return line to the oil tank. Tighten the hose
clamp securely, but do not over-tighten.
16. To prevent oil spillage, wait 3 to 5 minutes to allow any oil in the
oil filter cap to drain out before removing it. While waiting,
remove the foam oil breather element from the airbox. See page
97.
17. Inspect the foam element. Clean it with soap and water and let it
dry. Reinstall it, or install a new element if the existing element is
damaged or degraded and unable to absorb liquid.
18. Remove the oil filter cap, then remove the oil filter. Inspect the
o-ring and replace it if it’s worn or damaged.
19. Install a new filter, then reinstall the cap. Tighten the cap to 17 ft.
lbs. (23 Nm).
20. Remove the jumper from the starter motor wiring harness.
Reconnect the solenoid and the originally-installed harness.
Reinstall the 20A EFI Fuse.
21. Remove the dipstick from the oil tank. Add 2 quarts (1.9 liters) of
the recommended oil. Reinstall the dipstick.
95
MAINTENANCE
Engine Oil
Oil Change
22. Make sure the engine coolant temperature is between 145 and 160
degrees F. (63-71 degrees C). If necessary, start the engine and
allow it to idle until the coolant temperature is within the specified
range.
23. Remove the dipstick from the oil tank. Clean the dipstick with a
clean shop towel and reinstall it, screwing it in completely.
24. Remove the dipstick and view the oil level.
A. Fill mark for oil changes (at specified coolant temperature)
B. Safe operating range
A
B
25. Add additional oil to bring the level to the oil change fill mark (A).
See the chart for approximate amounts to add at this step. DO
NOT OVERFILL.
MODEL
NOTE:
Ounces
Milliliters
FS
4 to 16
118 to 473
FST
24 to 32
710 to 946
Check the oil level often during the fill procedure to avoid
overfilling. If the filling and checking procedure is not
completed within three minutes, reinstall the dipstick. Restart
the engine and allow it to idle for no more than 20 seconds to
circulate the oil back into the tank. Continue adding and
checking the oil until the level reaches the oil change fill
mark. Do not overfill.
26. Reinstall the dipstick.
96
OIL TO ADD AT STEP 25
Foam Oil Breather Element
MAINTENANCE
The foam oil breather element absorbs small amounts of liquid to
protect sensors within the intake system from damage due to oil
ingestion. Clean or replace the breather element at each engine oil
change. Clean the element if the snowmobile has been tipped on its left
side three times, either during service or while riding, as oil may leak
into the element.
CAUTION
Operating the snowmobile with a clogged foam oil breather
element can result in severe engine damage. Always clean or
replace the element as recommended.
The foam oil breather element is located inside the airbox.
A. FS foam element
B. FST foam element
1. Open the hood.
2. Release the airbox cover
retaining clips and remove the
cover.
3. Remove the foam breather
element.
4. Wash the foam element in soapy
water, then rinse thoroughly and
let dry.
NOTE:
A
B
If soap and water are not
readily available, remove as
much liquid as possible by
pressing the foam element
in paper towels or a similar
absorbent material.
5. Reinstall the dry foam element, or install a new foam element.
NOTE:
Always replace a foam element that is brittle, cracked,
crumbling or otherwise damaged. For best performance,
routinely replace the foam element with every other engine
oil change.
6. Reinstall the airbox cover. Secure all retaining clips.
97
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
pumps. Do not use more than four pumps.
Throttle Cable
Lubricate the throttle cable lightly with
grease or oil. With the engine off, turn
the handlebars to the left and lubricate
liberally as shown.
+
Front Suspension
The front suspension and steering components do not require
lubrication.
Rear Suspension
Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 88 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).
Lack of lubrication will adversely affect your ride and the life of the
suspension. For more information about suspension lubrication and
adjustments, see your Polaris dealer.
M-10 128 Rear Suspension
L
L
L
L
98
MAINTENANCE
Lubrication
M-10 136 Rear Suspension
L
L
L
L
Switchback Rear Suspension
L
L
L
L
L
99
MAINTENANCE
Lubrication
n Gearcase Oil
Check and change the gearcase oil
at the intervals outlined in the
Periodic Maintenance Table
beginning on page 88.
Polaris recommends the use of
Polaris Synthetic Chaincase Lube.
See page 133 for the part numbers
of Polaris products.
The dipstick (A) is located on the
lower front side of the gearcase.
Maintain the oil level in the safe
operating range (B), between the
upper and lower marks on the
dipstick.
A
Oil Check
1. Position the vehicle on a
level surface.
2. Remove the dipstick and
wipe it dry with a clean
cloth. Reinstall the
B
dipstick.
3. Remove the dipstick and
view the oil level.
4. Add the recommended oil as needed. Do not overfill.
5. Reinstall the dipstick.
100
Lubrication
MAINTENANCE
Gearcase Oil
Oil Change
The drain plug (A) is located on the
bottom of the gearcase.
NOTE:
Polaris does not recommend
tipping the snowmobile onto
it’s side for service. Any time
the snowmobile is tipped onto
it’s left side, always check the
oil level and clean the foam oil
breather element. See page
97.
1. Position the vehicle on a level
surface.
2. Remove the drain plug and drain
the oil into a drain pan. Allow
the oil to drain completely
NOTE:
3.
4.
5.
6.
The sealing surfaces on
the drain plug and the
gearcase should be clean
and free of burrs, nicks or
scratches.
A
Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
Remove the dipstick.
Add 9 oz. (266 ml) of the recommended oil. Do not overfill.
Reinstall the dipstick, making sure it is seated properly.
101
MAINTENANCE
Spark Plugs
A new engine can cause temporary spark plug fouling due to the
preservative added during the assembly process. Avoid prolonged idle
speeds, which cause plug fouling and carbonization.
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. A spark plug with a heat range too high will always
cause engine damage if the engine is operated in conditions more
severe than intended for that plug. Always use the spark plugs
recommended for your snowmobile.
S Use recommended spark plugs with the proper gap.
S Use only resistor-type spark plugs.
S Torque spark plugs to 18-20 ft. lbs. (24-27 Nm).
Check the spark plug firing end condition after the engine has been
warmed up and the vehicle has been driven at higher speeds. If a plug
is fouled, replace the plug using the tools provided in the tool kit.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE:
The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect throttle body adjustments.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil or
use of non-recommended injection oil.
102
Intake Filters
MAINTENANCE
+
The intake foam filter limits
snow ingestion into the intake
system. When operating in
loose powder snow, check the
top of the foam filter
periodically to remove any
accumulation of snow.
Fuel Injectors
All fuel injector service must be performed by an authorized Polaris
dealer. Do not attempt to clean or service the fuel injectors.
Fuel Pump
All fuel pump service must be performed by an authorized Polaris
dealer. Do not attempt to service the fuel pump.
Fuel Filter
See your Polaris dealer for replacement of the fuel filter at the intervals
outlined in the Periodic Maintenance Table beginning on page 88.
Fuel Lines
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal
deterioration from weather and fuel compounds may occur. Replace
worn or damaged fuel lines promptly.
CAUTION
Kinking the fuel lines or using a pliers or similar tools to remove
fuel lines may cause damage to the lines. If a fuel line has been
damaged or kinked, replace it promptly.
103
MAINTENANCE
Alternator Belt Inspection
Inspect the alternator belt condition and tension at the intervals
outlined in the Periodic Maintenance Table beginning on page 88.
1. Stop the engine.
2. Open the hood.
3. Inspect the belt for wear,
cracks or other damage.
If the belt is worn or
damaged, install a new
belt.
4. Grasp the alternator belt
and attempt to twist it.
5. If the belt rotates 1/4 turn
(90 degrees) or more (as
shown), tighten the belt or install a new belt.
Air Filter (FST)
Inspect the air filter for oil and dirt accumulation at the intervals
outlined in the Periodic Maintenance Table beginning on page 88.
1. Open the air box.
2. Remove the air filter.
3. Shake or pat the filter to clean it, or install a new filter. Do not
attempt to clean the filter with liquids.
Foam Oil Breather Filter
Clean or replace the breather element at each engine oil change. See
page 97. Clean the element if the snowmobile has been tipped on its
left side three times.
104
Exhaust System
MAINTENANCE
Check the exhaust system for wear or damage at the intervals outlined
in the Periodic Maintenance Table beginning on page 88.
WARNING
Hot exhaust system parts can cause serious burns. Allow
adequate time for the exhaust system to cool. Never perform this
procedure with the engine running.
1. Allow the engine and exhaust system to cool completely.
2. Open the hood.
3. Inspect the muffler and pipes for cracks or damage. Check for
weak or missing retaining springs or damper/support grommets.
4. Replace any damaged or missing components.
5. Clean the plastic surfaces next to the muffler with aerosol
Carburetor and Throttle Body Cleaner.
NOTE:
See page 133 for the part numbers of Polaris products.
6. Close the hood.
105
MAINTENANCE
Cooling System
Coolant
The coolant supplied in the system is a 60/40 mixture of
ethylene-glycol and distilled water. This mixture provides protection
against freezing. Contact your dealer if greater protection is required.
Use Premium 60/40 anti-freeze coolant, which is already premixed and
ready to use. Do not dilute with water. Never exceed a 60%
antifreeze/40% water mixture. See page 133 for the part numbers of
Polaris products.
NOTE:
Never add tap water to the cooling system. Minerals cause
deposits and may react adversely with the metals in the
engine and cooling system.
Use of a non-standard pressure cap will not allow the recovery system
to function properly. If the pressure cap needs replacement, contact
your dealer for the correct part.
n Coolant Level
The engine coolant level is controlled
by the recovery system. The recovery
system components are:
S Coolant bottle or overflow tank
S Filler neck
S Pressure cap
S Connecting hoses
Always maintain the coolant level at the
“COLD FILL” line (A) on the coolant tank
(when the engine is cold).
CAUTION
Operating the snowmobile with insufficient coolant will result in
overheating and serious engine damage. Always maintain the
coolant level as recommended.
106
A
Cooling System
MAINTENANCE
Coolant High Temperature Indicator Light
The high temperature indicator light will illuminate when engine
coolant temperature becomes too hot for safe continued operation of
the engine. If you must drive your snowmobile after the high
temperature indicator light has come on, drive slowly and stop
frequently to allow the engine to cool down. Driving in deep snow will
also help cool the engine. See your dealer for service. Add coolant if
the level is low.
NOTE:
Engine performance will be reduced if you continue operating
when the high temperature light is on.
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine,
the system should be completely drained every two years and a fresh
mixture of antifreeze and distilled water should be added. Have your
Polaris dealer perform this service.
Bleeding the Cooling System
Bleed the cooling system at the intervals outlined in the Periodic
Maintenance Table beginning on page 88. In addition, bleed the
cooling system any time one or more of the following conditions exist.
S A component of the cooling system has been serviced or replaced
(including coolers, radiator, engine, coolant lines and oil cooler)
S A cooling system failure occurs, resulting in coolant loss
S A coolant line has been disconnected for any reason
S A coolant leak occurs
107
MAINTENANCE
Cooling System
Bleeding the Cooling System
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
1. Read the entire coolant bleed procedure before beginning. After
beginning the bleed procedure, do not stop the engine until
reaching step 14.
2. Move the snowmobile into a well-ventilated area. Allow the engine
to cool completely.
WARNING
Steam and hot liquids will cause serious burns to your skin.
Never bleed the cooling system or remove the pressure cap when
the engine is warm or hot.
3. Open the hood.
4. Remove the coolant pressure cap (A)
carefully.
5. Slowly pour coolant into the filler
neck (B) until the coolant level
reaches the bleed return hole (C)
on the inside of the filler neck.
Leave the pressure cap off.
6. With the cap off, start the engine
and allow it to idle.
7. With the engine idling, observe the
coolant level in the filler neck. Make
sure that the coolant level in the filler
neck is always visible. When the
level falls, add coolant. A rising
level is acceptable.
NOTE:
108
A
B
C
During bleeding, air pockets will bubble to the surface. Add
coolant after these air pockets have surfaced, making sure
that the coolant level remains visible in the filler neck.
Cooling System
MAINTENANCE
Bleeding the Cooling System
8. With the engine idling, and while making sure that the level in the
filler neck remains visible, observe the bleed return. If the system
is self-bleeding properly, coolant will be pumped out of this hole.
NOTE:
Coolant flow may be erratic (spitting, misting) for the first few
minutes of bleeding, but as long as the procedure is followed
and coolant is visible in the filler neck, the system should
bleed properly.
9. While observing the bleed return and making sure the coolant level
is visible in the filler neck, observe the engine temperature in the
digital display. The temperature should rise steadily, indicating
that the system is bleeding properly.
10. If the temperature does not rise after approximately one (1) minute,
repeat steps 8 and 9. Make sure steps 8 and 9 are followed
precisely during the entire bleed procedure.
11. While the engine temperature is rising, allow the engine to idle
until the temperature reaches approximately 220° F (104° C). Do
not stop the engine at this step.
12. Feel the coolers at the rear of the snowmobile (rear cooler, de-icers,
grippers, as equipped). These components should be warm to the
touch, indicating the thermostat is open and the entire cooling
system is bleeding. If coolant is still flowing from the bleed return
and there is coolant in the filler neck, the system has been bled
properly. Do not stop the engine at this step.
13. Reinstall the coolant pressure cap while the engine is idling.
NOTE:
If the engine is stopped before the cap is installed, a large
amount of coolant will flow out of the filler neck and the entire
bleed procedure will have to be performed again.
14. Stop the engine.
15. Remove the coolant overflow tank cap. Add coolant to the
“COLD FILL” mark on the tank. Reinstall the cap.
109
MAINTENANCE
Drive Chain Tension
Check drive chain tension
weekly and before each long
trip. To obtain correct chain
tension:
1. Rotate the driven clutch
counterclockwise 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 (A).
3. Finger tighten the adjuster
bolt (B) until it can no longer
be adjusted by hand, then
back off 1/4 turn.
4. Tighten the jam nut while
holding the adjuster bolt.
Torque to 18-23 ft. lbs. (24-31 Nm).
5. Release the brake lever lock.
110
B
A
Brakes
n Hydraulic Brake Inspection
MAINTENANCE
Inspect the brake lever reserve before each use of the snowmobile. See
page 67.
Brake pads must be replaced when the brake pad material becomes
thinner than the backing plate, approximately 1/16″ (1.5mm). A kit is
available for replacing brake pads. See your dealer.
WARNING
Brake failure during operation can result in serious injury or
death. Properly functioning brakes are vital to your safety. Be
sure the brake pads do not drag on the disc and that brake lever
travel is not excessive.
Always replace brake pads when the brake pad material
becomes thinner than the backing plate, approximately 1/16″
(1.5mm).
Brake Components
A.
B.
C.
D.
E.
Brake Disc
Bleed Screw
Brake Line
Brake Caliper
Brake Pad Material Replace when
thickness is less than
1/16″ (1.5mm).
B
A
C
D
E
Excessive Lever Travel
Hydraulic brakes are
self-adjusting, but if excessive
brake pad clearance develops
bring the snowmobile to an
authorized Polaris dealer for
inspection and adjustment.
111
MAINTENANCE
Brakes
Brake Fluid
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or serious injury.
WARNING
Keep the master cylinder cover free of dirt and debris. The vent
slits allow for diaphragm movement, and if they become plugged,
movement of brake fluid below the diaphragm may be restricted,
altering brake function.
CAUTION
Brake fluid will damage decals, paint and some plastics. Always
wipe up spills immediately.
Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 133 for the part numbers of Polaris
products.
The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black.
If the sight glass is any color other than black, add brake fluid.
112
Brakes
MAINTENANCE
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING
Operating the vehicle with a spongy brake lever can result in loss
of brakes, which could cause an accident and lead to serious
injury or death. Never operate the vehicle with a spongy-feeling
brake lever.
During the bleeding procedure, keep the brake handle as level as
possible. The reservoir must be in this position to minimize the
possibility of air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16″ (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.
3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder
valve 3/4 of a turn to release air.
5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.
WARNING
Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or
death. Always add brake fluid to the fill line as recommended.
7. After bleeding is complete, refill the reservoir to the proper level.
See page 112.
8. Reinstall the gasket and cover.
113
MAINTENANCE
Lights
Removing Halogen Bulbs
NOTE:
Do not touch a halogen bulb with bare fingers. Oil from skin
leaves a residue, causing a hot spot that will shorten the life
of the lamp. If fingers do touch the bulb, clean it with an
alcohol-moistened towel.
1. Remove the plenum covering
from the headlight assembly.
B
2. Lift the rubber boot to expose
the bulb.
C
3. Push down on the spring (A)
to release it from the housing.
A
4. With the wire harness (B)
attached to the bulb (C),
withdraw the bulb from the housing.
5. Grasp the bulb by its metal base and carefully separate the bulb
from the harness.
Installing Halogen Bulbs
1.
2.
3.
4.
Hold the bulb by its metal base and install it into the wire harness.
Insert the bulb into the housing.
Connect the spring to the housing.
Carefully flip the spring back into the housing, placing it around
the wire harness.
5. Reinstall the plenum covering on the headlight assembly.
6. Adjust headlight aim. See page 30.
Replacing Taillight Bulbs
1. Remove the screws securing the taillight lens.
2. Push the bulb in and twist counterclockwise and replace the bulb.
3. Replace the taillight lens.
114
MAINTENANCE
Electrical System
RELAY LABEL
FUSE LABEL
Ground side of start
solenoid
START SOLENOID
RELAY
CHASSIS
RELAY
SPARE
20A
ACCESSORY
EMERGENCY
SPARE 30A
CHASSIS
30A
EX. SENSOR
GAUGE 20A
REVERSE SHIFT
IGNITION 20A
EFI
RELAY
EFI
20A
IGNITION RELAY
FUEL PUMP RELAY
FAN RELAY
ITEM POWERED
None
Accessory plugs
High beams
Low beams
Handwarmers
Thumbwarmer
Tail lamp
Brake lamp
Alternator coils
Exhaust sensor
Gauge
Reverse shift
Accessory projector beam relay
Diagnostic plug
Ignition relay power
Cam phase sensor
ECU hold-on power
Reverse limit switch
Forward limit switch
Start relay coil
Chassis relay coil
Ignition relay coil
Fuel pump relay coil
Fan relay coil
Fuel pump relay power
PTO injector
MAG injector
Wastegate
PTO Ignition Coil
MAG Ignition Coil
Fuel Pump
CAC fan
115
MAINTENANCE
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue.
To maintain optimum performance, clean with non-oil based cleaners
such as isopropyl alcohol.
WARNING
If you become aware of higher than normal clutch engagement or
an unusual vibration or shift pattern, see your dealer immediately.
Do not operate the snowmobile until repairs have been made.
All clutch maintenance and repairs must be performed by an
authorized Polaris dealer. Any unauthorized modifications to
clutches, such as adding or removing weights, will void the
warranty.
CAUTION
The bushings in the weights and rollers of Polaris clutches are
made of a material that may be damaged if lubricated. Do not
lubricate clutch bushings.
Clutch Alignment and Offset
Clutch alignment offset (A) is important for
maintaining optimum performance. See your
Owner’s Manual Supplement for the
recommended offset between the drive and
driven clutches with the belt removed.
Belt width and length must match the center
distance of the clutches and sheave width of the
drive clutch. Polaris recommends the use of
O.E.M. belts. Other belts may match the
dimensions, but can drastically change the shift
pattern, resulting in poor performance. See your
dealer for service and adjustments.
NOTE:
116
A worn belt will continue to function, but
will not deliver maximum performance.
Always carry a spare belt in case of an
emergency.
A
Clutch System
n Drive Belt Condition
MAINTENANCE
Periodically check the condition and tension of the drive belt, and
always carry a spare. Inspect the belt for signs of excessive wear:
frayed edges, missing cogs, cracks and excessive looseness. Replace
the belt if any of these conditions exist. See Drive Belt
Troubleshooting on page 140.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting
the snowmobile.
n Drive Belt Deflection
Measure belt deflection with both
clutches at rest and in their full
neutral position.
Place a straight edge on the belt (A)
and apply downward pressure while
measuring at point B. This
measurement should be 1 1/4” (3.2 cm).
A
B
Drive Belt Adjustment
TEAM Clutch
1. Loosen the 7/16” jam nut on the belt width adjuster.
2. Using a 1/8” Allen wrench, adjust the threaded set screw as
needed.
NOTE:
Turn the set screw in (clockwise) to increase the distance
between the sheaves and out (counterclockwise) to decrease
the distance.
3. Tighten the jam nut.
117
MAINTENANCE
Clutch System
Drive Belt Removal
CAUTION
Do not attempt to remove the drive belt after operating in reverse.
The snowmobile must be stopped after forward motion to prevent
damage to components during belt removal.
1. Stop the engine after operating in a forward motion.
NOTE:
For easier accessibility, make sure the clutch tool access
hole (+) is visible between the 11:00 and 2:00 positions of
the clutch sheave.
2. Turn the ignition key off.
Wait for the engine to come
+
to a complete stop.
2:00
11:00
3. Lock the parking brake.
4. Open the hood.
5. Remove the left side panel.
6. Locate the L-wrench in the
tool kit. Install the wrench
into the open threaded
access hole (+) in the outer
sheave of the clutch.
7. Turn the wrench clockwise until the sheaves open far enough to
remove the belt.
118
Clutch System
MAINTENANCE
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back the
slack.
NOTE:
To ensure satisfactory belt
life, install belts so they
operate 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
belt removal procedures.
2. Rotate the L-wrench counter-clockwise to tighten the sheaves
while working the belt to the outer edge of the sheaves.
3. Remove the wrench and store it in the tool kit.
4. Reinstall the side panel.
5. Close and secure the hood.
119
MAINTENANCE
Track Replacement
When replacing the track, always install a track having the lug size
recommended for your model. See your Polaris dealer.
CAUTION
Installing tracks with larger lugs on machines equipped with
coolers will result in damage to the cooler or tunnel. Always
install a track having the lug size recommended for your model.
Track Inspection
WARNING
Broken track rods can cause a rotating track to come off the
machine, which could cause serious injury or death. Never
operate with a damaged track. Never rotate a damaged track
under power.
1. Using a hoist, safely lift
and support the rear of
the snowmobile off the
ground.
2. Rotate the track by hand
to check for damage.
3. Carefully examine the
track along the entire
length of each rod (+).
Bend the track to check
for breakage.
4. Replace the track if any
rod damage is found.
+
120
Track Lubrication
MAINTENANCE
WARNING
Operating with insufficient lubrication between the rail slide and
track guide clips can cause track failure, loss of vehicle control
and loss of braking ability, which can result in serious injury or
death.
Avoid operating for extended periods on ice and other surfaces
that have little or no snow for lubrication.
The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new rail slide can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.
NOTE:
Track damage or failure caused by operation on ice or under
other poor lubrication conditions will void the track warranty.
CAUTION
High speed use on hard-packed surfaces is not recommended for
models equipped with a deep lug track. Track lug damage may
occur. Keep high speed use to a minimum, including frequent
slow-speed intervals for track cooling.
121
MAINTENANCE
Track Tension
WARNING
Moving parts 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 measurement
or adjustments with the engine running.
Track adjustment is critical for proper handling. Always maintain
correct tension and alignment.
Track Tension Data Chart
Suspension
Weight
Switchback
10 lbs. (4.54 kg)
M-10 128
M-10 136
NOTE:
Measurement
Location
Slack
Measurement
(C)
16″ ahead of rear
idler shaft
3/8″ - 1/2″
(1 - 1.3 cm)
10 lbs. (4.54 kg)
16″ ahead of rear
idler shaft
7/8″ - 1 1/8″
(2.2 - 2.9 cm)
10 lbs. (4.54 kg)
16″ ahead of rear
idler shaft
7/8″ - 1 1/8″
(2.2 - 2.9 cm)
Tension adjustments should be made only after the track is
warmed up and limber.
1. Turn the engine off.
2. Lift the rear of the snowmobile and safely support it off the
ground.
3. Place the recommended weight or downward pressure on the track
at the specified distance (see chart) ahead of the center of the rear
idler wheel.
NOTE:
Measure at the point where the weight is hanging.
10 lbs.
(4.5 kg)
16″
(40 cm)
122
MAINTENANCE
Track Tension
4. Check for specified slack (C) between the wear surface of the track
clip and the plastic rail slide.
If the track needs adjustment:
5. Loosen the rear idler shaft bolt (D).
6. Loosen the locknuts (A).
B
10 lbs.
(4.5 kg)
A
D
C
7. Tighten or loosen the track adjusting screws (B) as necessary to
provide equal adjustment on both sides of the track.
8. Repeat the measurement on the other side of the track.
NOTE:
Check more frequently when the snowmobile is new.
9. Start the engine and slowly rotate the track at least five revolutions.
Let the track come to a stop (do not apply brakes).
10. Check track alignment (see page 124) and adjust as necessary.
11. Tighten the locknuts (A).
12. Tighten the idler shaft bolts (D). Torque to 35 ft. lbs. (47.5 Nm).
123
MAINTENANCE
n Track Alignment
Periodically check that the track
is centered and running evenly
on the slide rails. Misalignment
will cause excessive wear to the
track and slide rail.
1. Safely support the rear of the
snowmobile with the track
off the ground.
2. Start the engine and apply a
small amount of throttle
until the track turns slowly at
least five complete
revolutions. Stop the engine
and let the track come to a
+
stop (do not apply brakes).
3. Inspect track alignment by looking through the track window to
make sure the rails (+) are evenly spaced on each side. If the track
runs to the left, loosen left locknut and tighten the left adjusting
bolt. If the track runs to the right, loosen right locknut and tighten
the right adjusting bolt.
4. After adjustments are complete, tighten locknuts and torque idler
shaft bolts to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
n Rail Slide
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 groove (+). Do
not operate the snowmobile if
slide thickness measures less
than 7/16″ (1.1 cm).
124
7/16″
(1.1 cm)
+
Steering System
MAINTENANCE
Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners
and tighten if necessary.
125
MAINTENANCE
Steering System
Ski Alignment
WARNING
Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Do not attempt to
change the ski alignment or camber adjustment. See your
Polaris dealer.
With the handlebars in a straight ahead position, and with vehicle
weight compressing the suspension, measure from the straight edge of
the skis at the center of the ski mounting bolt. The measurement
between the skis at point X should be 1/8″ to 1/4″ greater than the
measurement at point Y.
NOTE:
If the skis are misaligned, we recommend that your dealer
correct the alignment, since camber adjustment may also be
affected.
X
10″
10″
Y
126
Steering System
n Ski Skags
MAINTENANCE
WARNING
Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death.
See your dealer’s studding chart for recommended skags. If you
install longer or more aggressive carbide skags than the original
equipment, it may also be necessary to add track studs to
maintain proper vehicle control while turning on hard-packed
snow or ice.
Check skags before each use of the snowmobile to ensure positive
steering characteristics. Skags must be replaced when worn to half their
original diameter.
NOTE:
Carbide skags must be replaced if any abnormal wear or
chipping is found.
Skag Replacement
NOTE:
Some models are equipped with single skags. Other models
are equipped with dual skags.
1. Raise and support the
front of the snowmobile
so the skis are approximately
6″ (15.2 cm) from the ground.
2. Remove the attaching nuts
and pry the skag (+)
downward.
3. Remove the front end of
the skag.
4. Remove the rear end of
the skag.
5. Reverse the steps to
install a skag.
+
127
MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When
removing the battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always connect the
negative (black) cable last.
Battery Removal
1.
2.
3.
4.
5.
Remove the left side panel.
Disconnect the battery hold-down strap.
Disconnect the black (negative) battery cable first.
Disconnect the red (positive) battery cable last.
Lift the battery out of the vehicle.
Battery Installation
When installing a new battery, make sure it’s fully charged prior to its
initial use. Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also hinder
vehicle performance. Follow the battery charging instructions on page
129 before installing the battery.
1. Ensure that the battery is fully charged.
2. Set the battery in the battery holder.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Attach the hold-down strap.
6. Verify that cables are properly routed.
7. Reinstall the left side panel.
128
Battery
MAINTENANCE
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it’s fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE:
Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a
month to make up for normal self-discharge. Battery
Tendert can be left connected during the storage period,
and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Do not ever pry the sealing strip off or
add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is
to keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
129
MAINTENANCE
Battery
Battery Charging
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until thebattery voltage is 12.8 or greater.
NOTE:
When using an automatic charger, refer to the charger
manufacturer’s instructions for recharging. When using a
constant current charger, use the following guidelines for
recharging.
WARNING
An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the
battery becomes very warm to the touch. Allow it to cool before
resuming charging.
NOTE:
Always verify battery condition before and 1-2 hours after the
end of charging.
State of
Charge
Voltage
100%
12.8-13.0 volts
None, check at
3 mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75%
12.0-12.5 volts
Needs charge
5-11 hours
25%-50%
11.5-12.0 volts
Needs charge
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less
Needs charge with
desulfating charger
At least 20 hours
130
Action
Charge Time*
(Using constant current
charger @ standard amps
specified on top of battery)
Extended Storage
MAINTENANCE
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components. See page 133 for the part numbers of Polaris
products.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood,
chassis, and plastic parts. Wipe down remaining surfaces with a damp
cloth. Clean and touch up with paint any rusted or previously painted
surfaces. Be sure that corrosive salt and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors
(grease, oil or paint).
The snowmobile should be stored in a dry garage or shed, out of direct
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
Battery Maintenance
Remove the battery and recharge it as outlined on page 129. Store the
battery in a cool, dry place.
Controls and Linkage
Lubricate all bushings and cables at the intervals outlined in the
Periodic Maintenance Table beginning on page 88.
Bearings
Grease the jackshaft and drive shaft clutch side bearings with Polaris
Premium All-Season Grease or a similar high quality grease to prevent
corrosion.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Do not
lubricate clutch components, except the driven clutch shaft bushing as
outlined in the service manual. See your dealer.
131
MAINTENANCE
Extended Storage
Engine Protection
Fogging the engine is not recommended for this model.
CAUTION
Fogging the engine improperly can result in damage to the
sensors. Fogging is not recommended.
Electrical Connections
Replace worn or frayed electrical wire and connectors. Be sure wiring
harness is properly secured away from sharp edges, steering linkage,
moving parts, and hot exhaust parts.
Track and Suspension
Moderate track tension should be
maintained during summer
storage. The snowmobile should
be supported off the ground to
allow the track to hang freely.
See illustration.
Transporting the Snowmobile
Whenever the snowmobile is transported:
1. Be sure the fuel cap and oil cap are installed correctly.
2. Always tie the snowmobile to the transporting unit securely using
suitable straps.
3. Remove the ignition key to prevent loss.
132
POLARIS PRODUCTS
Part No.
Description
2874865
2874866
Engine Lubricants
Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt.)
Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (gal.)
Chaincase Lubricants
2873105
Synthetic Chaincase Lubricant (qt.)
2872951
Synthetic Chaincase Lubricant (12 oz.)
Grease / Specialized Lubricants
2871312
Grease Gun Kit, Premium All Season (3 oz.)
2871322
Premium All Season Grease (3 oz. cartridge)
2871423
Premium All Season Grease (14 oz. cartridge)
2871329
Dielectric Grease (Nyogelt)
Coolant
2871323
Anitfreeze, 60/40 Premix (gal.)
2871534
Anitfreeze, 60/40 Premix (qt.)
Additives / Miscellaneous
2871326
Carbon Clean Plus (12 oz.)
2870652
Fuel Stabilizer (16 oz.)
2872189
DOT4 Brake Fluid (12 oz.)
2872893
Engine Degreaser (12 oz.)
2870505
Isopropyl
2872889
Brake and Clutch Cleaner
2872890
Carburetor and Throttle Body Cleaner
133
TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Speed, RPM or Boost is Limited
Possible Cause
Solution
Engine Management System RPM
Reduction Mode is activated
See causes on page 34.
Jammed clutch
Check for twisted belt or broken spring.
See your dealer.
Jammed track
Remove any foreign objects. Slider may
be melted to the track clips due to lack of
lubrication. Track may be iced up or frozen to the ground.
Jammed or broken chaincase sprocket or
chain
See your dealer.
Mechanical failure
See your dealer.
Engine Doesn’t Turn Over
Possible Cause
Solution
Low battery voltage
Recharge the battery to 12.8 VDC.
Loose battery connections
Check all connections and tighten.
Loose solenoid connections
Check all connections and tighten.
Engine stop switch is off
Lift the stop switch to the ON position.
Fusable link malfunction
See your dealer.
Fuse panel malfunction
Check condition of fuses. Replace blown
fuses, then see your dealer.
Main relay panel malfunction
See your dealer.
Mechanical failure
See your dealer.
134
TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Turns Over, Fails to Start
Possible Cause
Solution
Out of fuel
Refuel.
Water is present in fuel
See your dealer.
Old or non-recommended fuel
Replace with fresh recommended fuel.
Fouled or defective spark plugs
Inspect plugs and replace if necessary.
No spark to spark plug
See your dealer.
Water or fuel in crankcase
See your dealer.
Clogged fuel filter
Replace the filter.
Low battery voltage
Recharge the battery to 12.8 VDC.
Poor engine compression
See your dealer.
Mechanical failure
See your dealer.
Engine Backfires
Possible Cause
Solution
Weak spark from spark plug
Inspect, clean and/or replace spark plugs.
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs.
Old or non-recommended fuel
Replace with fresh recommended fuel.
Mechanical failure
See your dealer.
Loose ignition connections
Check all connections and tighten.
Water present in fuel
Replace with fresh recommended fuel.
Exhaust manifold leak
Inspect and repair, or see your dealer.
135
TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Engine Runs Irregularly, Stops or Loses Power
Possible Cause
Solution
Engine Management System RPM
Reduction Mode is activated
See causes on page 34.
Low battery voltage
Recharge the battery to 12.8 VDC.
Water is present in fuel
See your dealer.
Poor quality or low octane fuel
Replace with fresh recommended fuel.
Loose ignition connections
Check all connections and tighten.
Incorrect spark plug gap or heat range
Set gap to specs or replace plug.
Fouled or defective spark plug
Inspect, clean and/or replace spark plug.
Kinked or plugged fuel vent line
Inspect and replace.
Clogged air filter
Inspect and clean or replace.
Air flow through intake is too warm (FST
only)
Boost is limited until cooler air flows
through the intake.
Engine management system failure
See your dealer.
Engine overheating
See the “Engine Overheating” troubleshooting section.
Fuel in crankcase
See your dealer.
Drive clutch binding
See your dealer.
Incorrect clutching
See your dealer.
Driven clutch malfunction
See your dealer.
Worn drive belt
Replace with the recommended belt.
Excessive belt/sheave clearance
See your dealer.
Loose torque stop
Inspect and adjust.
Other mechanical failure
See your dealer.
Engine Overheating
Possible Cause
Solution
Low snow conditions
Drive into snow frequently. See page 20.
Low coolant
Check the coolant level. See page 106.
Check for leaks. Bleed the system if the
coolant level is extremely low.
Restricted air flow to radiator
Clean snow and debris from the radiator.
136
TROUBLESHOOTING
Engine and Drive Train Troubleshooting
Harsh Drive Clutch Engagement
Possible Cause
Solution
Worn drive belt
Replace with the recommended belt.
Excessive belt/sheave clearance
See your dealer.
Drive Belt Turns Over
Possible Cause
Solution
Incorrect belt
Replace with the recommended belt.
Incorrect clutch alignment
See your dealer.
Broken or loose engine mount
See your dealer.
Drive System Noise
Possible Cause
Solution
Broken drive clutch components
See your dealer.
Bearing failure (chaincase, jackshaft or
front drive shaft)
See your dealer.
Flat spots on drive belt surface
Inspect and replace as needed.
Loose drive chain
Inspect and adjust (or replace).
Worn drive chain/broken sprocket teeth
See your dealer.
137
TROUBLESHOOTING
Suspension Troubleshooting (Switchback)
Problem
Solution (perform only one change at a time)
Rear suspension
bottoms too easily
S Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Increase shock compression damping (see page 53).
Rear suspension
rides too stiff
S Check for binding suspension components and grease all
pivot points.
S Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Decrease shock compression damping (see page 53).
Too much weight
transfer when
climbing
S Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Move limiter strap on front torque arm to high position (see
page 51).
Too little weight
transfer when
climbing
S Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Move limiter strap on front torque arm to low position (see
page 51).
Front end pushes
S Check for worn skags
S Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine).
S Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Increase IFS preload (see page 47).
S Move limiter strap on front torque arm to high position (see
page 51).
Steering is heavy
S
S
S
S
Machine darts from
side to side
S Ensure skis are properly aligned (see page 126).
S Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine).
S Ensure skags are straight on skis.
138
Check skags and skis for damage.
Check ski alignment (see page 126).
Make sure spindles and all steering components turn freely.
Verify sag dimension (see page 50). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Adjust IFS preload (see page 47).
S Adjust RIDER SELECT (see page 31).
TROUBLESHOOTING
Suspension Troubleshooting (M-10)
Problem
Solution (perform only one change at a time)
Rear suspension
bottoms too easily
S Increase FRA position (see page 56).
S Install appropriate optional center retainer on rear track shock
(see page 57).
S Increase front track shock coil spring preload.
S Revalve rear track shock compression damping (see your
dealer).
S Check track tension (see page 122).
Rides too stiff in
rear
S Decrease FRA position (see page 56).
S Install appropriate optional center retainer on rear track shock
(see page 57).
S Decrease front track shock coil spring preload.
S Revalve rear track shock compression damping (see your
dealer).
S Check track tension (see page 122).
Front end pushes
S Check for worn skags
S Check for binding suspension shafts and grease all pivot
points.
S Shorten front limiter strap.
S Install single skags (see your dealer).
Steering is heavy
S
S
S
S
Machine darts from
side to side
S Make sure skis are aligned properly.
S Make sure spindles and all steering components turn freely.
S Check for excessive play in steering assembly
(see your dealer).
S Make sure skags are straight on skis.
S Set static sag (see page 54).
S Install dual skags.
Check skags and skis for damage.
Check ski alignment (see page 126).
Make sure spindles and all steering components turn freely.
Verify sag dimension (see page 54). Adjust torsion spring
blocks or install optional torsion springs to achieve correct
sag dimensions.
S Adjust IFS preload (see page 47).
S Adjust RIDER SELECT (see page 31).
139
TROUBLESHOOTING
Drive Belt Troubleshooting
Belt Wear/Burn Diagnosis
Causes
Solutions
Driving at low RPM
S Drive at higher RPM. Gear the machine down. Check
belt deflection.
Insufficient warm-up
S Warm the engine at least five minutes. Take the drive belt
off the machine in extremely cold weather and warm it
up. Break machine loose from the snow.
Towing at low RPM
S Do not tow in deep snow. Use fast, aggressive throttle to
engage clutch.
Riding with high RPM
and slow speed (8000
RPM/10 MPH)
S Lower the gear ratio. Reduce RPM. Avoid riding in
high ambient temperatures. Check for snow ingestion.
Ice and snow build-up
between track and
tunnel
S Warm the engine at least five minutes. Take the drive belt
off the machine in extremely cold weather and warm it
up. Break machine loose from the snow.
Poor engine
performance
S Check for fouled plugs or water, ice, or dirt in the gas
tank or fuel line.
Loading machines onto
trailers
S Skis may gouge into trailers and prevent the drivetrain
from spinning properly. Use enough speed to drive the
machine completely onto the trailer. Push and pull it to
finish loading if necessary.
Clutch malfunction
S Inspect clutch components. See your dealer.
Slow, easy clutch engagement
S Use fast, aggressive throttle to engage clutch.
Wrong or missing belt
S Always use the recommended belt.
Improper break-in
S Always break in a new belt and/or clutch by avoiding
aggressive or high speed operation during the break-in
period.
140
Service And Warranty Information
WARRANTY
Obtaining Service and Warranty Assistance
Read and understand the service data and the Polaris warranty
information contained in this manual. Contact your Polaris dealer for
replacement parts, service or warranty. Your dealer receives frequent
updates on changes, modifications and tips on snowmobile
maintenance, which may supersede information contained in this
manual. Your dealer is also familiar with Polaris policies and
procedures and will be happy to assist you.
When contacting us about parts, service, or warranty, always provide
the following information:
1. Serial number 5. Details of trouble experienced
2. Model number 6. Length of time and conditions of operation
3. Dealer name
7. Previous correspondence
4. Date of purchase
Use the page provided near the front of your Owner’s Manual to record
the identification numbers of your snowmobile and its engine.
Polaris Customer Service
United States: 1-763-417-8650
Canada: 1-204-925-7100
Polaris Anti-Theft System
The Polaris anti-theft system (PATS) monitoring program is designed
to aid owners of registered snowmobiles in recovery of stolen
machines.
Administration
1. Polaris snowmobile owner reports theft.
A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service.
B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines.
2. Polaris warranty will provide all dealerships with a monthly
updated list of all stolen units to further monitor thefts.
3. Polaris warranty will aid in notifying the proper owner when a unit
is recovered.
141
WARRANTY
Limited Warranty
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. The warranty begins on
the date of purchase. This warranty is transferrable to another consumer, during the warranty period, through a Polaris dealer.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and setup of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
setup will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures not caused by a defect in material or workmanship.
The warranty does not cover accidental damage, normal wear and tear, abuse or improper
handling. The warranty also does not cover any snowmobile that has been structurally
altered, neglected, improperly maintained, used for racing or used for purposes other
than for which it was manufactured. The warranty does not cover any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this
warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion or defects in parts, components or the snowmobile due to fire, explosions or any other cause beyond Polaris’ control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,
repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the
above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
142
WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations
on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controlling state law.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris snowmobiles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (The cost of transportation to
and from the dealer is YOUR responsibility). Polaris recommends that you use your
original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Your dealer will contact the
appropriate personnel at Polaris if additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms
will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
143
WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested by
a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign
the PDI form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage. Use
of the recommended Polaris products for lubrication and maintenance as directed by the
Owner’s manual is highly recommended. Should a failure occur during the warranty
period resulting from the use of non-recommended products, warranty coverage may be
denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty consideration if the failure was due to wear or not the direct result of a defect:
Skis
Ski wear rods
Tracks
Slide rails
Suspension components
Finished and unfinished surfaces
Brake components
Carburetor/Throttle body components
Seat components
Engine components
Clutches and components
Drive belts
Steering components
Hydraulic components
Batteries
Circuit breakers/Fuses
Light bulbs/Sealed beam lamps
Electronic components
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered “consumable,” meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Lubricants such as oil, grease, etc.
Filters
Batteries (unless defective)
Fuel
Cosmetic damage/repair
Sealants
Coolants
Hotel fees
Meals
Towing charges
Shipping/ handling fees
Mileage
Product pick-up/delivery
Rentals/Loss of product use Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or
contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance
ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty
period expires or by an unauthorized repair center; use of the product in competition or
for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or
workmanship.
144
WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused
snowmobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is
transferable 120 days after the original purchase date, free of charge, through any Polaris
snowmobile dealer. Coverage on Snow Check units is automatic. Although you do not
receive a warranty card, your dealership should have printed a copy of the warranty
registration form. This form is your proof of warranty.
Consumer Exclusions
S Each repair visit after the first twelve months of standard warranty coverage is subject
to a $50 deductible.
S The free Second Year Engine Service Contract applies to the first 5,000 miles or two
(2) calendar years from date of purchase, whichever comes first. Tampering with the
odometer shall void all warranties/service contracts. No extensions to coverage under
this engine service contract can be given. Used snowmobiles are not eligible under
this program.
S Snowmobiles used for commercial purposes or for racing are excluded from coverage.
Coverage
Coverage for second year engine failures due to defects in materials and workmanship
will be determined by Polaris in its sole discretion. Coverage is automatic with no
additional paperwork required. The free Second Year Engine Service Contract is subject
to a $50 deductible per visit. Regular, documented service maintenance visits are
required to validate this warranty.
A partial list of items excluded from coverage includes:
S Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.
S Damage caused by the failure of other components of the snowmobile.
S Failures caused by improper fuel or oil.
S Piston seizures, unless caused by a defective engine component.
S Failures caused due to improper adjustments.
S Failure due to unauthorized service.
S Failures due to lack of service as required in the owner’s manual or Polaris updates.
This includes off-season storage as listed in the owner’s manual.
S Failure due to use of unauthorized parts or modifications.
S Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and
exhaust manifolds excluding paint coverage.
S Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring
and other electrical components are excluded from coverage.
S Cooling system coverage is limited to the water pump assembly and components, fan,
fan bearings, temperature sensor, gasket and seals.
S Non wear related throttle body parts are covered. The fuel pump is covered.
S Clutches and related clutch parts, including but not limited to, the drive belt, are excluded from coverage.
S Electrical components are excluded from coverage.
S Gearcases and transmissions are excluded from coverage.
145
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance (see page 141).
146
WARRANTY
Snowmobile Engine Emissions Limited Warranty
This snowmobile engine emissions limited warranty is in addition to the Polaris standard
limited warranty for snowmobiles.
Polaris Industries Inc. warrants that the new engine, including all parts of its emissioncontrol system, is designed, built and equipped so it conforms to current U.S. Environmental Protection Agency regulations applicable to snowmobile emissions under 40
CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants
that the engine is free from defects in materials and workmanship that may keep it from
meeting these regulations.
The warranty period for this emissions certified snowmobile engine starts on the date
when the engine is first purchased and continues for 4000 kilometers (2485 miles) of
vehicle travel, 200 hours of operation, or 30 calendar months, whichever comes first.
This engine emissions limited warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. This includes components whose failure increases the snowmobile engine’s emissions. To the extent they are
present on your snowmobile engine, this includes electronic controls, fuel injection components, exhaust gas recirculation system components, and aftertreatment system components. Replacing or repairing other components not covered by this warranty is the
responsibility of the snowmobile owner.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option
of Polaris, repair or replacement of any defective materials, components or products.
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE
LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN.
POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS
WARRANTY.
147
WARRANTY
Snowmobile Engine Emissions Limited Warranty
Some states do not allow limitations 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 caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or
use. This limited warranty also does not cover any engine that has been structurally altered,
or any engine that has been used in racing competition. This limited warranty also does not
cover physical damage, corrosion or defects caused by fire, explosions or other similar
causes beyond the control of Polaris.
Owners are responsible for performing the scheduled maintenance identified in the owner’s
manual. Polaris can deny an emissions warranty claim if any specified critical emissions--related maintenance is not performed. Performance of other scheduled maintenance is strongly recommended, but is not necessary to keep the emissions--related warranty valid.
Any qualified repair shop or qualified person may maintain, replace, or repair the emission
control devices or systems on your snowmobile. Polaris recommends that you contact an
authorized Polaris dealer to perform any service that may be necessary.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with
emission controls is prohibited by federal law and may result in civil penalties.
148
MAINTENANCE LOG
Present this section of your manual to your dealer each time your
snowmobile is serviced. This will provide you and future owners with
an accurate log of maintenance and services performed on the
snowmobile.
DATE
MILES (KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
1500 mi.
(2400 km)
149
MAINTENANCE LOG
DATE
150
MILES (KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
151
INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . .
Adjustable Headlights . . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . .
Alternator Belt Inspection . . . . . . . .
Avalanches . . . . . . . . . . . . . . . . . . . .
D
61
30
104
104
16
B
Battery . . . . . . . . . . . . . . . . . . . 128-130
Battery Charging . . . . . . . . . . . . 129-130
Battery Installation . . . . . . . . . . . . . 128
Battery Jumping . . . . . . . . . . . . . . 76-77
Battery Removal . . . . . . . . . . . . . . . 128
Battery Storage . . . . . . . . . . . . . . . . 129
Bearings . . . . . . . . . . . . . . . . . . . . . 131
Bleeding the Cooling System . . 107-109
Bleeding, Hydraulic Brake System . 113
Brake Components . . . . . . . . . . . . . 111
Brake Fluid . . . . . . . . . . . . . . . . . . . 112
Brake Lever Travel . . . . . . . . . . . . . . 67
Brake, Park . . . . . . . . . . . . . . . . . . . . 68
Brakes . . . . . . . . . . . . . . . . . . . . 111-113
Break-In Period . . . . . . . . . . . . . . . . . 74
Bulb Replacement . . . . . . . . . . . . . . 114
C
Carbide Skags . . . . . . . . . . . . . . . . . . 63
Cargo Overload . . . . . . . . . . . . . . . . . 12
Cargo Rack . . . . . . . . . . . . . . . . . . . . 30
Check After Starting the Engine . . . . 71
Check Before Starting the Engine . 65-70
Check Engine Indicator . . . . . . . . . . . 33
Cleaning and Preservation . . . . . . . . 131
Clutch Alignment . . . . . . . . . . . . . . 116
Clutch and Drive System . . . . . . . . 131
Clutch Cover . . . . . . . . . . . . . . . . . . . 23
Clutch System . . . . . . . . . . . . . . 116-119
Clutches . . . . . . . . . . . . . . . . . . . . . . 19
Cold Weather Drive-Away . . . . . . . . 19
Controls and Linkage . . . . . . . . . . . 131
Coolant . . . . . . . . . . . . . . . . . . . . . . 106
Coolant Level . . . . . . . . . . . . . . . . . 106
Cooling System . . . . . . . . . . . . 106-109
152
Daily Storage . . . . . . . . . . . . . . . . . . 84
Deep Snow . . . . . . . . . . . . . . . . . . . . 20
Detonation Elimination Technology . 36
Digital Display Identification . . . . . . 37
Disabled Operators . . . . . . . . . . . . . . 12
Drive Belt . . . . . . . . . . . . . . 19, 117-118
Adjustment . . . . . . . . . . . . . . . 117
Condition . . . . . . . . . . . . . . . . 117
Deflection . . . . . . . . . . . . . . . . 117
Installation . . . . . . . . . . . . . . . 119
Removal . . . . . . . . . . . . . . . . . 118
Drive Chain Tension . . . . . . . . . . . . 110
Driver Awareness . . . . . . . . . . . . . . . 15
Driveshaft Bearing . . . . . . . . . . . . . . 98
Driving Downhill . . . . . . . . . . . . . . . 17
Driving in Hilly Terrain . . . . . . . . . . 18
Driving on Slippery Surfaces . . . . . . 18
Driving Responsibly . . . . . . . . . . . . . 21
E
Electrical Connections . . . . . . . . . . 132
Electrical System . . . . . . . . . . . . . . . 115
Electronic Reverse . . . . . . . . . . . . . . 82
Emergency Starting . . . . . . . . . . . . 76-77
Emergency Stopping . . . . . . . . . . . . . 83
Emission Control Information . . . . 85-86
Engine Management System . . . . . 33-35
Engine Protection . . . . . . . . . . . . . . 132
Engine Safety . . . . . . . . . . . . . . . . . . 10
Engine Stop Switch . . . . . . . . . . 71, 80
Excessive Speed . . . . . . . . . . . . . . . . 14
Exhaust System . . . . . . . . . . . . . . . . 105
F
Flushing the Cooling System . . . . .
Foam Oil Breather Element . . . . . . . .
Fogging the Engine . . . . . . . . . . . . .
FRA Position, M10 . . . . . . . . . . . . . .
Front Shock Spring Preload . . . . . . .
Front Springs . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . .
Fuel Injectors . . . . . . . . . . . . . . . . .
Fuel Level . . . . . . . . . . . . . . . . . . . . .
107
97
132
56
47
48
79
103
103
79
INDEX
F
Fuel Lines . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . .
Fuel Safety . . . . . . . . . . . . . . . . . . . .
Fuel System Deicers . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . .
O
103
103
73
79
115
G
Gauge Cleaning . . . . . . . . . . . . . . . . 45
Gearcase Oil . . . . . . . . . . . . . . . 100-101
Grab Handle Adjustment . . . . . . . . . 61
H
Halogen Bulbs . . . . . . . . . . . . . . . .
Handlebar Adjustments . . . . . . . . . . .
Headlights . . . . . . . . . . . . . . . . . . . . .
High Temperature Indicator . . . . . .
Hydraulic Brake Inspection . . . . . . .
114
60
30
107
111
I
Ice and Snow Build-up . . . . . . . . . . . 17
IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 46
IFS Components . . . . . . . . . . . . . . . . 46
Inadequate Snow Conditions . . . . . . 20
Instrumentation . . . . . . . . . . . . . . . 37-45
Intake Filters . . . . . . . . . . . . . . . . . . 103
Intake Silencer . . . . . . . . . . . . . . . . . 19
L
Lighting Check . . . . . . . . . . . . . . . . . 71
Lights . . . . . . . . . . . . . . . . . . . . . . . 114
Limiter Strap Position . . . . . . . . . . . . 51
Lubrication . . . . . . . . . . . . . . . . . 98-101
M
Maintenance Interval Table . . . . . . 88-90
Maintenance Log . . . . . . . . . . . 149-151
Malfunction Indicator Lamp . . . . . . . 33
Maneuverability . . . . . . . . . . . . . . . . 19
MFD Battery Replacement . . . . . . 44-45
MFD Component Identification . . . . 37
MFD Digital Display Programs . . 39-43
MFD Settings . . . . . . . . . . . . . . . . . . 38
Mirror Adjustment . . . . . . . . . . . . . . 71
Oil Breather Element . . . . . . . . . . . . . 97
Oil Change . . . . . . . . . . . . . . . . . . 94-96
Oil Level Check . . . . . . . . . . . . . . 92-93
Oil, Engine . . . . . . . . . . . . . . . . . . 91-96
Operating in Deep Snow . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . 26, 73-84
Operator Safety . . . . . . . . . . . . . . . . 8-22
P
Passenger . . . . . . . . . . . . . . . . . . . . . 24
Passenger Grab Handle Adjustment . 61
Passenger Seat . . . . . . . . . . . . . . . . . . 29
PERC . . . . . . . . . . . . . . . . . . . . . . . . 82
Polaris Products . . . . . . . . . . . . . . . 133
Pre-Ride Checklist . . . . . . . . . . . . . . 64
Pre-Ride Inspections . . . . . . . . . . . 64-72
Pressure Cap . . . . . . . . . . . . . . . . . . . 23
R
Radiator Compartment Access . . . . . 30
Rail Slide . . . . . . . . . . . . . . . . . . . . 124
Rear Spring Preload, M10 . . . . . . . . . 57
Recommended Maintenance . . . . . . . 87
Reverse . . . . . . . . . . . . . . . . . . . . 25, 82
Rider Capacity . . . . . . . . . . . . . . . . . 13
RIDER SELECT
Adjustable Steering System . . 31-32
Riding Apparel . . . . . . . . . . . . . . . . . 12
Riding Position . . . . . . . . . . . . . . . . . 11
Rollover Inspections . . . . . . . . . . . . . 72
S
Safety Decals and Locations . . . . . 23-26
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sag/Ride Height, M10 . . . . . . . . . 54-59
Seat, Passenger . . . . . . . . . . . . . . . . . 29
Service And Warranty Information . 141
Shock Compression Damping,
Rear Track . . . . . . . . . . . . . . . . . 52
Shock Damping . . . . . . . . . . . . . . . . 47
Shock Valving . . . . . . . . . . . . . . . . . . 48
Shocks, Rear . . . . . . . . . . . . . . . . . . . 53
Signal words . . . . . . . . . . . . . . . . . . . . 8
Skag Replacement . . . . . . . . . . . . . . 127
153
INDEX
S
T
Skags . . . . . . . . . . . . . . . . . . . . . . . . 63
Ski Alignment . . . . . . . . . . . . . . . . . 126
Ski Pressure, M10 . . . . . . . . . . . . . 58-59
Ski Skags . . . . . . . . . . . . . . . . . . . . 127
Slide, Rail . . . . . . . . . . . . . . . . . . . . 124
Snow Conditions . . . . . . . . . . . . . . . 20
Spark Plugs . . . . . . . . . . . . . . . . . . . 102
Spring Preload . . . . . . . . . . . . . . . . . 50
Starting the Engine . . . . . . . . . . . . . . 75
Starting, Emergency . . . . . . . . . . . 76-77
Steering Adjustment . . . . . . . . . . . . 125
Steering Inspection . . . . . . . . . . . . . 125
Steering System . . . . . . . . . 66, 125-127
Stop Switch . . . . . . . . . . . . . . . . . 71, 80
Stopping . . . . . . . . . . . . . . . . . . . . . . 83
Storage . . . . . . . . . . . . . . . . 84, 131-132
Storage Compartments . . . . . . . . . . . 29
Studs . . . . . . . . . . . . . . . . . . . . . . . . . 62
Survival Preparation . . . . . . . . . . . . . 11
Suspension Storage . . . . . . . . . . . . . 132
Suspension, Front, IQ . . . . . . . . . . 46-48
Suspension, Rear . . . . . . . . . . . . . . . . 49
Suspension, Switchback . . . . . . . . 50-53
Suspension Inspection, Pre-Ride . . . . 70
Suspension Performance Tips . . . . . . 49
Suspension, Rear, M10 . . . . . . . . . 54-59
Symbols . . . . . . . . . . . . . . . . . . . . . . . 8
Taillight/Brakelight Replacement . . 114
Throttle Cable . . . . . . . . . . . . . . . . . . 98
Throttle Lever . . . . . . . . . . . . . . . . . . 81
Throttle Safety Switch . . . . . . . . . . . 80
Tip-Over Inspections . . . . . . . . . . . . . 72
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 87
Torsion Spring Tension . . . . . . . . . . . 51
Towing . . . . . . . . . . . . . . . . . . . . . . . 84
Track . . . . . . . . . . . . . . . . . . . . . 24, 132
Track Alignment . . . . . . . . . . . . . . . 124
Track Inspection . . . . . . . . . . . . . . . 120
Track Inspection, Pre-Ride . . . . . . . . 69
Track Lubrication . . . . . . . . . . . . . . 121
Track Replacement . . . . . . . . . . . . . 120
Track Safety . . . . . . . . . . . . . . . . . . . 10
Track Tension . . . . . . . . . . . . . . 122-123
Track Tension Data . . . . . . . . . . . . . 122
Track Warm-Up . . . . . . . . . . . . . . . . 78
Traction Products . . . . . . . . . . . . . 62-63
Transporting the Snowmobile . . . . . 132
Troubleshooting . . . . . . . . . . . . 134-140
Drive Belt . . . . . . . . . . . . . . . . 140
Engine and Drive Train . . . 134-137
M-10 Suspension . . . . . . . . . . 139
Switchback Suspension . . . . . . 138
Trunk . . . . . . . . . . . . . . . . . . . . . . . . 29
Turbo Noise . . . . . . . . . . . . . . . . . . . 81
V
Valve Lash . . . . . . . . . . . . . . . . . . . . 90
Vehicle Identification Numbers . . . . . . 7
W
Warning Labels . . . . . . . . . . . . . . . 23-26
Warranty . . . . . . . . . . . . . . . . . . 141-148
Wear Strips . . . . . . . . . . . . . . . . . . . . 63
Windchill/Temperature Charts . . . . . . 22
154