Polaris Trail Touring User's Manual

Pantone 280 CVC
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9922285 Rev 01
Printed in USA
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.
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 worldwide family of Polaris enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at Polaris we proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• 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.
Copyright 2009 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.
2010 Trail Touring Owner's Manual
P/N 9922285
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 29
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 45
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . .111
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 112
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 128
Record maintenance and service in the log for your reference and for
future owners of the vehicle.
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3
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.
Vehicle Model Number: ___________________________________________________
Tunnel VIN:_____________________________________________________________
(lower right side of the tunnel)
Engine Serial Number: ____________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
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.
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.
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.
4
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education campaign. We encourage governments 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.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction
of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
5
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, indicates the potential
for serious injury.
WARNING
A WARNING indicates a potential hazard that may result in serious injury or
death.
CAUTION
A CAUTION indicates a potential hazard that may result in minor injury.
NOTICE
A NOTICE indicates a situation that may result in damage to the vehicle.
6
Operator Safety
SAFETY
Follow the recommended maintenance program beginning on page 70
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.
7
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.
8
Operator Safety
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 21.
WARNING! Avoid wearing loose clothing
or long scarves, which can become
entangled in moving parts and cause
serious injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
051039
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
9
SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, 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.
Use of a backrest may hinder your weight shifting ability. This could
affect your ability to control this rider-active vehicle in certain extreme
driving situations.
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:
•
•
•
•
•
10
Spare Drive Belt
Extra Set of Spark Plugs
Tow Rope
Extra Oil
Fuel Deicer
•
•
•
•
Winter Survival Kit
Trail Map
Owner's Manual
First Aid Kit
Operator Safety
SAFETY
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
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.
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. See page 23 for decal
location.
Machines 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 machine 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.
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.
11
SAFETY
Excessive Speed
Always observe all 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 machine travels. If your speed is 40 MPH, your machine is
traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH,
your machine 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 machine to a stop in the distance illuminated by the headlight.
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.
12
SAFETY
Operator 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 machine 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.
R
R
13
SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• 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 the American
and Canadian online avalanche centers at www.avalanche.org.
14
Operator Safety
SAFETY
Ice and Snow Build-up
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.
WARNING! Ice and snow build-up may interfere with the steering of your
machine, resulting in serious injury or death. Keep the underhood area free of
snow and ice.
Driving on Slippery Surfaces
WARNING! Driving on ice or hard-packed snow reduces steering and braking
control, which may result in serious injury or death. Slow down and use caution.
If driving on ice or other slippery surfaces is unavoidable, use extreme
caution and operate at speeds no faster than a walk. Never attempt an
abrupt change of direction. The chance of “spin-out” increases under
these conditions.
15
SAFETY
Operator Safety
Driving Downhill
When riding downhill, shift your weight to the rear of the machine 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
machine 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.
16
Operator Safety
SAFETY
Driving in Hilly Terrain
WARNING! Climbing a hill or crossing the face of a slope may result in loss of
balance and machine roll-over, 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 machine to
maintain proper balance and avoid possible roll-over.
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 machine 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 machine, pull the rear of the snowmobile around and point
the front end and skis downhill. Remount the machine, restart the
engine, release the parking brake, and descend the hill carefully.
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.
17
SAFETY
Operator Safety
Clutch Guard
Do not operate the engine with the clutch guard removed.
The clutch guard is designed to protect the operator from metal parts if
the clutch should fail. Although the chance of failure is extremely
remote, don't defeat the purpose of the safety guard by removing it.
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 machine into motion, but always operate within
safety limits.
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
machines designed to carry a load.
Maintenance
Follow the recommended maintenance program beginning on page 70
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.
18
Operator Safety
SAFETY
Inadequate Snow Conditions
Moveable hood closures are included on some Polaris snowmobiles.
They are normally left open and are located on the front upper and lower
hood openings. If operating in deep snow or in extreme cold conditions
(below -20_ F), Polaris recommends closing the upper hood closure.
NOTICE: Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine. Do not drive for prolonged periods
on blacktop, gravel, or ice. If frequently operating in low cooling conditions, see your dealer for an optional wheel kit that will reduce the
wear from overheating.
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 machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track
and/or engine.
If the machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when the
throttle is opened, the snowmobile will be able to climb up and over the
snow.
19
SAFETY
Operator 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 machine and with
what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before
attempting ambitious maneuvers.
• 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.
• Before allowing someone else to 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.
• Don't “jump” your snowmobile over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. 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.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• 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.
• Remove the key from the ignition when you leave the snowmobile
unattended.
20
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
WINDCHILL CHART (_F)
Wind
Speed
40
in
MPH
Actual Thermometer Reading (_F)
35
30
25
20
15
10
5
0
-5
-10 -15 -20 -25 -30 -35 -40 -45
Equivalent Temperature (_F)
40
35
30
25
20
15
10
5
5
36
31
25
19
13
7
1
-5
10
34
27
21
15
9
3
-4
-10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
15
32
25
19
13
6
0
-7
-13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
20
30
24
17
11
4
-2
-9
-15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
25
29
23
16
9
3
-4
-11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84
30
28
22
15
8
1
-5
-12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
35
28
21
14
7
0
-7
-14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
40
27
20
13
6
-1
-8
-15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
45
26
19
12
5
-2
-9
-16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
50
26
19
12
4
-3
-10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
55
25
18
11
4
-3
-11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
60
25
17
10
3
-4
-11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
Frostbite in >> 30 min.
0
-5
-10 -15 -20 -25 -30 -35 -40 -45
Calm
-11 -16 -22 -28 -34 -40 -46 -52 -57 -63
10 min.
5 min.
WINDCHILL CHART (_C)
Wind
Speed
in
KPH
5
2
-1
-4
-7
-10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Actual Thermometer Reading (_C)
Calm
5
2
-1
-4
-7
-10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
-11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57
Equivalent Temperature (_C)
8
3
0
-4
-7
16
2
-2
-6
-10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62
24
1
-3
-7
-11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65
32
0
-4
-8
-12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67
40
-1
-5
-9
-13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69
48
-1
-5
-9
-13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
56
-2
-6
-10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
64
-2
-6
-10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
72
-2
-7
-11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
80
-3
-7
-11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
88
-3
-7
-12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
96
-3
-8
-12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
Frostbite in >> 30 min.
10 min.
5 min.
21
SAFETY
Safety Decals and Locations
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:
WARNING
Do not operate engine 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.
Air Box Warning
This warning decal is found under the hood on applicable models:
CAUTION
Do not operate above 40 mph with hood-to-air box foam removed
or engine failure will result.
22
SAFETY
Safety Decals and Locations
Track Warning
The track warning decal is on the
rear of the tunnel:
+
WARNING
Stay clear of track. Do not sit on
seat back. Entanglement with the
track or a fall from seat back can
result in severe injury or death.
Passenger Warning
Polaris touring models are
designed for the operator and
one passenger. For more information on operating with a passenger, see page 11.
The passenger warning decal is
located at the right side of the
steering post:
WARNING
+
This vehicle is designed for
operator and ONE passenger
only.
23
SAFETY
Safety Decals and Locations
Electronic Reverse Warning
Polaris snowmobiles equipped
with electronic reverse have a
reverse warning decal on the
lower dash:
WARNING
Reverse operation, even at low
speeds, can cause loss of control resulting in serious injury
or death. To avoid loss of control, always:
• Look behind before and
while backing up.
• Avoid sharp turns.
• Shift to or from reverse only
when stopped.
• Apply throttle slowly.
+
For more information, see Owner's Manual.
If electric reverse:
• Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse operation.
• Push button again to return to forward.
• Elevation setting (above 6000 feet): push and hold for longer than 5
seconds to set. Let go of button at desired setting-fast flash for high
elevation, slower flash for low. Setting will remain until changed.
24
Safety Decals and Locations
SAFETY
Operation Warning
The operation warning decal is located on the console:
WARNING
• To avoid serious injury or death, read and understand all warnings
and the Owner's Manual before operation. If manual is missing, contact a Polaris dealer for a replacement.
• 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.
• 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.
• Never consume alcohol or drugs before or while operating this vehicle.
• 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.
• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
• This vehicle is designed for adult use only. Check local laws for age
requirements.
• 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.
• 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.
• 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.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• 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.
25
FEATURES
Some Polaris snowmobiles are equipped with special features. Operating controls and special feature controls are illustrated on this page. Not
all models come with all special features. See your Owner's Manual
Supplement.
5
4
General
Representation
6
3
7
8
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
26
1
Fuel Filler Cap
Ignition Switch
Brake Lever
Speedometer
Tachometer
Engine Stop Switch
Throttle Control
Hood Hold-Down Straps
Choke
Recoil Starter Handle
Parking Brake Lock
Handlebar Grip Warmer Switch
Thumbwarmer Switch
Electronic Reverse Button
Headlight Dimmer Switch
9
10
11
13
12
15
14
FEATURES
9
5
8
7
6
4
3
2
1
10
11
12
13
1. Front Bumper (do not use for pulling
or dragging the snowmobile)
2. Hood
3. Headlight
4. Windshield
5. Handlebar
6. Operator Seat
7. Passenger Grab Handle
8. Passenger Seat
9. Passenger Backrest
10. Suspension
11. Track
12. Trailing Arm
13. Nosepan
14. Ski
15. Taillights
16. Rear Bumper
17. Snow Flap
14
15
16
17
27
FEATURES
Backrest
The backrest is adjustable for either
operator or passenger use.
1. Loosen the upper adjustment
knobs to raise or lower the
backrest.
2. Loosen the lower adjustment
knobs to move the backrest
forward for operator use or
rearward for passenger use.
3. Always tighten the knobs
securely after adjusting.
28
Raise/Lower
Operator/Passenger
THE PERFECT FIT
Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail conditions. We recommend starting with
factory settings and then customizing each adjustment individually to
suit rider preference. The machine 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. Trailing arms
IFS Adjustment Options
• Front shock spring preload
• Optional springs
• Toe (ski alignment) (see
page 100)
• Camber (see your dealer)
4
2
1
3
29
THE PERFECT FIT
Front Suspension Adjustments
WARNING! Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Always verify ski alignment before
making adjustments to the IFS. See page 100 to check alignment. Do not
attempt to change the ski alignment or camber adjustment. See your Polaris
dealer.
For the best ride, the suspension should be adjusted to use the full travel
of the shocks with occasional light bottoming. To determine if your
machine is using full travel, push the jounce bumper down on the shock
rod until it contacts the body and test ride the machine. The bumper will
move up on the rod in relation to the amount of travel that was used during the ride. If the travel is full, the bumper will be seated at the top of
the rod.
Shock Components
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.
1. Retainer
2. Shock Rod
3. Jounce Bumper
4. Body
5. Threaded Spring Preload Adjuster
Nut
30
1
2
3
4
5
THE PERFECT FIT
Front Suspension Adjustments
Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing
spring preload will decrease ski-toground pressure. When adjusting, be
sure the springs on both the left and right
sides of the machine are at the same
adjustment.
To increase front shock spring preload,
grasp the spring and turn it to the right.
Turn it to the left to decrease preload.
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
Low
High
suspension. Never exceed one inch of
Preload
Preload
preload beyond the factory settings, and
ensure that both sides are adjusted the
same. When decreasing preload, make
sure at least two turns of preload are holding the spring between the
retainer on top of the shock and the threaded spring preload adjuster nut
on the shock body.
Tip: Not all models have shocks with thread adjustable spring preload. See your
dealer for more information.
NOTICE: Always leave one thread showing above the adjuster nut. On models
equipped with a plastic adjuster nut, if the nut is unscrewed from the
threaded body, the nut will break.
Front Springs
For models without externally adjustable or revalvable shocks, 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.
31
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 snowcross racing would provide a
very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snowcross course.
See your Polaris dealer for initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to
one area at a time so you can evaluate the change. For further assistance,
see your dealer.
32
THE PERFECT FIT
Rear Suspension Adjustments
Suspension Performance Tips
• 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 setup. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.
• In deep snow, a new rail slide will offer improved performance over
worn rail slide. It can also improve top speed.
• When riding on ice or hard-packed snow, adding a set of bogie wheels
to the rail may enhance the machine's performance. Bogie wheel kits
are available from your dealer.
• Polaris offers track kits for improved flotation in deep snow. See your
dealer for assistance.
Tip: 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. See
page 74.
Track Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 96.
33
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the EDGE rear suspension
torsion spring preload, measure the
distance between the ground and
rear bumper. This is measurement
X.
Take the first measurement with no
rider and with the rear suspension at
full extension.
X
Tip: The rear bumper may need to be
lifted upward slightly to fully extend
the rear 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
Y
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. Use the illustration for reference. The ideal amount of
Sag for the EDGE rear suspension is four inches (X-Y=4).
If the rear suspension rides in less than three inches or more than five
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 set-up, and final spring preload may
vary based on rider preference and riding conditions.
34
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Rear 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. See your dealer for more information.
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.
Low Tension
Medium Tension
High Tension
35
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Indy Select Rear Shock
Some snowmobiles are equipped with the Indy Select rear shock, which
allows for adjustments to the compression valving. Locate the adjustment screw near the base of the shock. In half-turn increments, turn the
screw clockwise to increase compression valving and stiffen the ride, or
counterclockwise to reduce compression and soften the ride. There are
approximately three full turns of adjustment available.
If bottoming continues after the screw has been turned fully clockwise,
the torsion spring should be adjusted (see page 35). Return the screw to
its original starting position after the torsion spring has been tightened.
Adjustment Screw
36
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Optional Torsion Springs
Different rate torsion springs are available for some shocks if a firmer
ride is desired. Contact your dealer for more information.
Suspension Coupling
On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each
other. Rear suspension coupling links the movement of the front and
rear torque arms to each other. There are two types of rear suspension
coupling.
Front To Rear Coupling and the Front Rear Scissor Stop
(FRSS)
The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque
arm.
When hitting a bump, the front torque arm starts to compress. The FRSS
links that movement to the rear torque arm, causing it to compress and
raise the rear suspension up as one, allowing the suspension to hit the
bump only once and reducing kickback.
The factory setting is usually adequate for all riders and conditions.
37
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Suspension Coupling
Rear To Front Coupling and the Rear Rear Scissor Stop
(RRSS)
The rear rear scissor stop (RRSS) couples the movement of the rear
torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.
Adjusting the RRSS either allows more weight to transfer to the rear for
more traction, or allows less weight to transfer to the rear, resulting in
improved cornering performance. An adjustment dot is located on the
RRSS. This dot is on the longest end of the scissor stop.
Moving the RRSS to a higher position will have the following effects on
the suspension:
• Reduced weight transfer.
• Improved chatter bump ride.
• Improved cornering performance.
38
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
Weight Transfer During Acceleration
The preferred method for controlling
weight transfer during acceleration
is by adjusting the rear rear scissor
stop (RRSS). The factory setting is
the best for most trail riding conditions.
To decrease weight transfer under
acceleration (for improved cornering), rotate the RRSS to a higher
position.
To increase weight transfer or ski lift
during acceleration, move the RRSS
to the rearward hole on high position. The RRSS may also be rotated
to a lower position for even more
weight transfer if desired.
Stock Position - This setting is most
desirable for trail riding.
Medium or High Position (standard
hole location) - This setting will
decrease weight transfer.
Rearward Upper Position
(optional hole location - This setting
will increase weight transfer.
Stock
Medium/High
Rearward Upper
Tip: Your dealer can help you with initial
setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also
available from your dealer.
39
THE PERFECT FIT
Handlebar Adjustment
Follow these steps to adjust handlebar angle at the handlebar block.
1. Remove the handlebar cover
to expose the handlebar and
Cover
the four adjuster block bolts.
2. Using a 7/16-inch wrench,
loosen the four nuts on the
Bolts
bottom of the adjuster block
(turn the handlebar either left
or right for access to the rear
nuts). If necessary, pry the
blocks apart with a screwdriver.
3. Adjust the handlebar to the
desired angle. Be sure the
Nuts
handlebar, brake lever and
throttle lever operate
smoothly and do not hit the
gas tank, windshield or any
other part of the machine
when the handlebar is turned fully to the left or right.
4. Torque the front bolts first, then torque the rear bolts. Torque the
bolts to 11-13 ft. lbs. (15-18 Nm).
5. Reinstall the handlebar cover.
40
Traction Products
THE PERFECT FIT
Studs
Before equipping your machine with traction products, be aware of the
laws in your area pertaining to the use of traction products. See your
dealer about installing studs and/or carbides. Many tracks with deep lug
designs cannot be studded, but your dealer will be able to offer advice
and assistance.
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.
NOTICE: Always install wear strips before installing studs. Failure to install wear
strips may result in cooler or tunnel damage. See page 43.
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.
NOTICE: Aggressive studding patterns may require that you grind 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 inches (2.86
cm) from the outside edge of the track.
41
THE PERFECT FIT
Traction Products
n Carbide Skags
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 101.
If your machine 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.
Inspect skags and studs frequently. Worn studs or skags may reduce
steering and braking control on hard-packed snow and ice. Replace
worn studs and skags to maintain proper balance and vehicle control.
WARNING! Loss of control can result in serious personal injury or death.
Proper balance of traction products on the skis and track must be maintained to
obtain proper vehicle control on hard-packed snow or ice. See your dealer for
assistance.
42
Traction Products
THE PERFECT FIT
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. See your dealer for more information.
Wear strips are designed for a specific stud length. See your dealer's
studding chart for recommended traction accessories.
Components as viewed from the rear of the track:
1. Top of tunnel
2. Wear strip
3. Track
4. Wear strip mounting holes
2
1
4
3
NOTICE: 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.
43
THE PERFECT FIT
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:
• Non-compliance with government/industry requirements
• Voiding of warranty
• Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems.
Tip: Exhaust systems are critical safety areas that must use approved Polaris
parts. Please see your Polaris dealer for service.
44
Pre-Ride Checklist
PRE-RIDE INSPECTIONS
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
See Page
89, 92
Steering System
49
Recoil Rope
50
Parking Brake Lock/Brake Lever/Brake System
47, 48, 84
Auxiliary Shut-Off Switch (Engine Stop Switch)
51
Ignition Switch
51
Taillight/Brakelight/Headlight
51
Suspension Mounting Bolts
106
Skags (Wear Bars)
101
Ski Saddle and Spindle Bolts
106
Hood Straps/Latches
50
Seat Latches (if equipped)
50
Throttle Lever/Safety Switch
62, 63
Rear Wheel Idler Bolts
97
Tether Switch/Strap
N/A
Track Alignment/Condition
49, 98
Rail Slide Condition
99
Chaincase Oil Level
76
Injection Oil Level
59
45
PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.
WARNING! Operating the vehicle with worn, damaged, or malfunctioning
components coule result in serious injury or death. Never start the engine
without checking all vehicle 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 machine is operated.
See page 62.
46
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Hydraulic Brakes
Always check the following items for proper operation before starting
the engine.
Brake Lever Travel
Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2I (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 86 or see your
dealer for service.
1/2 inch (1.3 cm)
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Also check for the presence of air in the fluid system. See page 85 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.
47
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Parking Brake Lever Lock
Your snowmobile may have a
parking brake lever lock located
over the brake lever. Use the
brake lever lock only when you
want the machine to remain stationary; for example, when
parked on an incline for a period
of five minutes or less.
1. Brake Lever
2. Parking Brake Lever Lock
(if equipped)
3. Master Cylinder Reservoir/
Cover
4. Fluid Level Indicator
2
3
4
1
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.
NOTICE: 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 brake light on the console will light up if the parking brake lever
lock is set while the engine is running. It will also be lit when the service
brake is in use. If the parking brake light does not come on when the
parking brake or service brake is in use, have it serviced by your dealer.
Lock Release
To release the lock, squeeze the brake lever tightly and release it. The
lock will return to the unlocked position.
WARNING! If the parking 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.
48
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Steering System
WARNING! Ice and snow build-up may interfere with the steering of your
machine, 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. Make sure all greasable components are properly
lubricated.
n Track
WARNING! Always inspect the track for damage before using the vehicle.
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.
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 with inadequate lubrication could severely damage track rods,
break track edges, and cause other track damage. Examples of inadequate lubrication would include frozen bodies of water without snow
cover, icy trails, and no-snow conditions.
Track damage or failure caused by operation on ice or under poor lubrication conditions voids the track warranty.
49
PRE-RIDE INSPECTIONS
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 Seat Latches
If your snowmobile is equipped with a removable seat, ensure that the
seat latches are securely in place before every use of the snowmobile.
n Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure the
knot securing the rope inside the handle is secure. If excessive wear is
found, see your Polaris dealer for replacement.
50
PRE-RIDE INSPECTIONS
Start the Engine and Check
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 the 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 machine.
51
OPERATION
Starting the Engine
NOTICE: Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
1. Turn the fuel valve on. See
page 57.
2. Turn the key to the ON
position.
3. Pull the engine stop switch
up to the RUN position.
4. If starting a cold engine,
flip the choke toggle to
FULL CHOKE. Do not use
the choke if starting a warm
engine.
CHOKE POSITIONS
OFF
1/2 CHOKE
FULL CHOKE
CAUTION! Do not depress the throttle until the engine starts.
CAUTION! To avoid injury and/or engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.
5. If equipped with electric start, turn the key to START to crank the
engine. Release the key to the ON position when the engine starts.
NOTICE: Don't pull the starter rope to the fully extended position and don't allow
it to snap back into the housing. Damage may result.
6. If not equipped with electric start, grasp the recoil rope handle and
pull slowly until the recoil engages; then pull abruptly to crank the
engine.
7. Repeat the cranking procedure as needed until the engine starts.
8. After the engine starts, flip the choke toggle to the OFF position. If
the engine slows or wants to stop, use intermittent choking to the
HALF CHOKE position.
52
Engine Break-In
OPERATION
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of fuel with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection
system, will assure proper engine break-in.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts. Do not operate at full throttle or high
speeds for extended periods during the first three hours of use. Vary
the throttle openings and machine speeds to reduce friction on all
close-fitting machined parts, allowing them to break in slowly without
damage.
Use of any lubricants other than those recommended by Polaris may
cause serious engine damage. We recommend the use of Polaris
lubricants for your vehicle.
Drive with extra caution during the break-in period. Perform regular
checks on fluid levels, lines, and all other important areas of the
machine.
53
OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. See page 59.
NOTICE: Serious engine damage can occur without the proper lubrication.
Check the oil tank level often during the first tank of fuel. If the oil level
doesn't go down, contact your dealer immediately.
Oil Recommendations
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of Premium 2-Cycle Oil for this
engine. See page 111 for the part numbers of Polaris products.
Never mix brands of oil. Serious chemical reactions can cause injection
system blockage, resulting in serious engine damage. Oils may also be
incompatible and the result could be sludge formation, filter blockage,
and reduced cold weather flow rates. All Polaris oils are compatible
with each other.
54
Track Warm-Up
OPERATION
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
about 4 inches (10 cm) off the ground.
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. Use a stable rear
support.
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.
Tip: 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 machine to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
55
OPERATION
Slide Rail and Track Cooling
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide
rail and track, resulting in premature wear and failure. Reduce speeds
and frequently drive into fresh snow to allow adequate cooling and
polishing of the slide rail and track surfaces. Avoid operating on ice,
hard-packed surfaces or roads.
Fuel
WARNING! Gasoline is highly flammable and explosive under certain
conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• 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.
• Turn the fuel valve off whenever the snowmobile is stored or parked.
Exhaust
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.
56
OPERATION
Fuel
Fuel Valve
Turn the fuel valve clockwise to
OFF to shut off the fuel supply.
Turn the valve counter-clockwise
to ON to turn the fuel supply on.
OFF
ON
Fuel Recommendations
Your Polaris engine is designed to run on 87 octane non-oxygenated or
89 octane oxygenated pump gasoline. There's a great deal of variability
in the quality of the 87 octane gasoline available across the country, so
we encourage the use of premium fuel when possible. Do not use fuel
containing more than 10% ethanol (including E85).
NOTICE: Using fuels with a lower than recommended octane or operating with
obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine.
57
OPERATION
Fuel
Fuel Reserve Capacity (Mechanical Gauge)
There are approximately two gallons of fuel left in the tank when the
mechanical fuel gauge reads RES.
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 111 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.
NOTICE: Prolonged exposure to petroleum based products may damage paint.
Always protect painted surfaces when handling fuel.
58
n Oil
Low Oil Indicator Light
OPERATION
The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. If oil is not visible, continued operation may cause serious engine damage. Add oil before further operation
of the snowmobile.
Low Oil Level
Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage. This is
especially important when the machine is operated in mountainous terrain.
Always check the oil level when refueling. When the oil reaches the low
level mark, add one quart (.9 l) of recommended oil to the tank. See
page 54 for oil recommendations.
NOTICE: Operating the snowmobile without adequate engine lubrication can
result in serious engine damage. Always check the oil level when refueling. Add oil as needed.
The Polaris oil cap on the oil bottle is vented to allow proper oil flow.
See your Polaris dealer for recommended replacement parts.
59
OPERATION
Carburetion
Proper carburetor adjustment is critical. Always have your Polaris
dealer perform any carburetor adjustments.
A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too
much fuel, too little air) may foul plugs and cause generally poor engine
performance.
A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may
be caused by snow build-up on the pre-filter in the air intake system.
Either condition may be caused by improper carburetor adjustment.
60
Carburetion
OPERATION
Jetting Guidelines
Changes in altitude and temperature affect air density, which is the
amount of oxygen available for combustion. In low elevations and cold
temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.
The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and
ambient temperatures from +5 to +25 degrees F. (-15 to -4 degrees C.).
Carburetors must be re-calibrated if the snowmobile is operated outside
this production temperature and/or altitude range. The main jet installed
in production is not correct for all altitudes and/or temperatures. See
page 81 for more information.
NOTICE: A main jet that's too small will cause a lean operating condition and
may cause serious engine damage. Jet the carburetors carefully for
elevation and temperature according to the jetting charts in your
Owner's Manual Supplement.
Tip: It's the owner's responsibility to ensure that the correct jets are installed in
the machine for a geographical area. Be very careful when jetting down in
warm weather. As the weather turns colder it will be necessary to re-jet
upward to prevent engine damage. When selecting the proper main jet
always use the lowest elevation and temperature that is likely to be encountered.
61
OPERATION
n Engine Stop Switch
Push down on the engine
stop switch (+) to
ground out the ignition
and stop the engine
quickly. Pull the switch
up to the ON position to
allow restarting.
+
n Throttle Safety Switch
The throttle safety switch is designed to stop the 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 carburetor/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
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.
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
62
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 carburetor 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.
Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
machine 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
machine with the throttle safety switch disconnected. Return the
machine to an authorized Polaris dealer for service as soon as possible.
63
OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 62 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
Choke
Floods engine
Half throttle or less
Engine Stop Switch
Interrupts ignition circuit
All
Throttle Safety Switch
Interrupts ignition circuit
All
Tether Switch (if available)
Interrupts ignition circuit
All
WARNING! Excessive or repetitive use of brakes for high speed stops will
cause an overheated brake system. This overheated condition could cause
sudden loss of brakes and/or fire, resulting in serious injury or death. When
traveling on long downhill stretches, pump the brakes. Riding the brakes may
cause the brake system to overheat and result in brake failure.
64
Electronic Reverse (PERCt)
OPERATION
Electronic reverse will activate only if the engine RPM is below 4000. If
your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described on page 67. Always make sure the vehicle is
stopped and the engine is running at idle before shifting to reverse.
WARNING! Improper reverse operation, even at low speeds, may cause loss of
control, resulting in serious injury or death. Damage will occur to the chaincase
or transmission if shifting is attempted when the engine is operating above idle
speed.
• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.
• Look behind the vehicle before and while backing.
• Avoid sharp turns.
• Apply throttle slowly.
65
OPERATION
Electronic Reverse (PERCt)
Engaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Make sure the area behind your vehicle is clear.
3. Push the yellow reverse button (+) on the left-hand control for one second, then
release. The engine will automatically reduce RPM and
start a reverse rotation. A
flashing reverse light on the
instrument panel will indicate
that the transmission is in
reverse.
4. Apply the throttle slowly to
make sure the transmission is
in reverse.
+
Tip: The maximum engine RPM will be 6000 when in reverse.
Tip: If the engine stops running, the snowmobile will be in forward gear when it's
restarted.
66
Electronic Reverse (PERCt)
OPERATION
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
NOTICE: Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
2. Push the yellow reverse button for one second and release. The
engine will slow and begin to rotate forward. The light on the
instrument panel will shut off.
3. Apply the throttle slowly to make sure the transmission is in forward.
Altitude Setting
At higher altitudes (above 6000 feet), the engine will require a different
ignition setting to improve the success of the reverse system. To set for a
higher altitude, start the engine and hold the button down until the light
on the instrument panel flashes rapidly, then release the button.
To set the reverse for lower elevations, continue holding the button
down until the reverse indicator light blinks slowly. Once set, it's stored
in memory until changed, whether the machine is running or not.
67
OPERATION
Towing
Do not use the front bumper to pull or drag the snowmobile. The front
bumper is not designed for this type of use and may detach from the
vehicle if force is applied.
For your safety, do not attempt to use a tow hitch until you've read the
following warnings and understand the proper hitch functions.
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.
NOTICE: 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.
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 4I (10
cm) off the ground. Remove the key and
cover the machine.
68
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. 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.
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty, and
read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris
recommends that you contact an authorized Polaris dealer to perform
any service that may be necessary.
69
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 128.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1000 miles (1600 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile
(1600 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.
NOTICE: 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.
70
MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.
Item
See
Page
Frequency
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
I
I
PreSeason
CLUTCH
Clutch Alignment Offset
(without belt)
89
I
Drive Belt Condition
89
I
I
I
Clutches (disassemble)
89
C
C
C
I
Belt Tension
--
I
I
I
I
Clutch Sheaves
89
I
I
I
I
ENGINE/COOLING
Engine Mounts
--
I
I
I
I
Recoil Rope
--
I
I
I
I
Engine Mounting Plate
--
I
I
I
Engine Torque Stop
93
I
I
I
Cylinder Head Bolts
--
I
I
I
Cylinder Base Nuts
--
Ignition Timing BTDC
--
Spark Plug Condition
77
Exhaust Pipe
83
Exhaust Retaining
Springs
83
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
71
MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
PreSeason
BRAKES
Hose Routing
--
I
I
I
I
Hose Condition
--
I
I
I
I
Fluid Leaks
--
I
I
I
I
Brake Pads
84
I
I
I
I
Brake Disc
--
I
I
I
I
Parking Brakes
48
I
I
I
Brake System
47, 84
Brake Fluid
I
I
85
R
FUEL MANAGEMENT
Pilot Air Screws
--
I
I
I
Carburetor
(synchronize)
81
I
I
I
I
I
I
I
I
I
Idle RPM
--
Throttle Lever
63
Oil Pump Lever
(synchronize)
--
I
I
I
Throttle Cable
75
L
L
L
Choke Cable
75
L
L
L
Choke
75
I
I
I
Vent Lines
--
I
I
I
Fuel Lines
80
I
I
I
I
Oil Lines
--
I
I
I
I
I
I
Air Box
--
Drain and Water Traps
82
I
Auxiliary Shut-Off
Switch
51
I
Throttle Safety Switch
62
Ignition Switch
--
Taillight
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
51
I
I
I
I
I
Brakelight
51
I
I
I
I
I
Headlight
51
I
I
I
I
I
ELECTRICAL
72
MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
PreSeason
CHASSIS
Ski Toe Alignment
--
I
I
I
Suspension Mounting
Bolts
--
I
I
I
I
I
Steering Fasteners
--
I
I
I
I
C
Rear Suspension Fasteners
--
I
I
I
I
I
Suspension Shock Oil
--
I
I
I
I
Cooling Fins and
Shroud
--
I
I
I
I
Drive Shaft Bearing
75
L
L
L
I
Jackshaft Bearings
108
I
I
I
I
Skags (Wear Bars)
101
I
I
I
I
I
Ski Saddle/Spindle Bolts
--
I
I
I
I
I
Ski Pivots
74
L
L
L
L
I
Ski Spindle
74
L
L
L
L
Steering Arm(s)
--
Upper / Lower Steering
Post Support Bracket
74
L
L
L
L
I
Drive Chain Tension
83
I
I
I
I
I
Hood Latches
50
I
I
I
I
I
Battery Fluid Level
102
I
I
I
I
I
Rear Wheel Idler Bolts
97
I
I
I
I
I
Idler Bolt Jam Nut
97
I
I
I
I
Rear Suspension Pivot
Shafts
74
L
L
Camber Alignment
--
I
I
Radius Rod Bushings
--
Handlebar Centering
--
Track Alignment
98
I
I
I
I
I
Track Tension
96
I
I
I
I
I
Front Limiter Strap
--
I
I
I
I
Rail Slide Condition
99
I
I
I
L
I
I
I
I
I
Chaincase Oil
76
I
I
I
R
I
Gearcase Oil
N/A
I
I
I
R
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
73
MAINTENANCE
Lubrication
Suspension and Steering
Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every
1000 miles (1600 km) thereafter. See page 111 for the part numbers of
Polaris products.
The illustration shows the lubrication points of suspension and steering
components. A + indicates a grease point or fitting.
• Grease the left and right spindles. Raise the front end of the machine
to permit better grease entry into the spindle area.
• Lubricate both of the front ski pivots at the fittings as shown.
• Grease the driveshaft clutch side bearing.
• Use an aerosol lubricant on the steering post support bracket.
• Grease the steering post lower pivot.
• Grease the rear suspension pivot shafts (raise the rear of unit).
A grease gun kit, complete with grease and adaptors, is available to
lubricate all fittings on Polaris snowmobiles.
+
+
+
+
74
+
MAINTENANCE
Lubrication
EDGE 136 Rear Suspension
+
+
+
+
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.
+
Choke and Choke Cable
Lubricate the choke slide and cables
lightly with oil or grease. Before
turning the engine off, operate the
choke intermittently to draw moisture out of the choke plunger area
and reduce the possibility of the
choke becoming frozen.
+
75
MAINTENANCE
Lubrication
n Chaincase Oil
Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 70. Change the chaincase oil after the
first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.
Maintain the oil level between the “safe” marks on the dipstick. Clean
the magnetic plug on the dipstick whenever checking or changing oil.
Polaris recommends the use of Polaris Synthetic Chaincase Lube. See
page 111 for the part numbers of Polaris products.
Oil Check
1. Position the vehicle on
a level surface.
2. Remove the dipstick (1)
and view the oil level
on the dipstick.
3. Add the recommended
oil as needed. Do not
overfill.
4. Clean the magnetic
plug (2).
5. Reinstall the dipstick.
76
2
1
Spark Plugs
MAINTENANCE
It’s very important to use the correct spark plug for your machine. A
spark plug with a heat range too high will cause engine damage. A spark
plug with a heat range too low will cause excessive fouling and engine
malfunctioning.
NOTICE: 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. See your Owner’s Manual Supplement.
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.
• Use recommended spark plugs with the proper gap. See your Owner’s
Manual Supplement.
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too
light in color. Before changing spark plug heat ranges, be sure the correct
main jet is installed in the carburetor(s). Refer to the Owner's Manual Supplement or see your dealer.
77
MAINTENANCE
Spark Plugs
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect carburetor/throttle
body adjustments.
Wet Fouled 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, use
of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Wear protective gloves.
2. Remove the spark plug cap.
3. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
4. Reverse the procedure for spark plug installation.
5. Torque the spark plug to specification. See page 77.
6. Verify that gap is within specification. See your Owner’s Manual
Supplement.
7. Reinstall the spark plug cap.
78
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.
NOTICE: Operating the snowmobile with the intake filters removed may cause
carburetor icing. The result will be poor fuel economy or carburetor
malfunction. Always reinstall the intake filters before operating the
snowmobile.
These illustrations are general representations. Your model may differ.
+
+
79
MAINTENANCE
Fuel Filter/Fuel Lines
The fuel filter is located inside the fuel tank. This component requires
no maintenance.
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.
NOTICE: 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.
Oil Filter
The oil filter on your model is assembled into the oil sending unit
located in the bottom of the oil tank. This component requires no maintenance.
If service is performed to the oil injection system, trapped air must be
bled from the system. See your dealer for instructions, or have your
dealer perform this service.
80
Carburetor
MAINTENANCE
The number stamped in the end of the main jet indicates the jet size. The
jet installed at the time of manufacture is not necessarily correct for your
elevation. It's your dealer's responsibility to make sure the correct main
jet is installed.
NOTICE: Operating the snowmobile with incorrect jetting can result in serious
engine damage. Have your Polaris dealer perform all carburetor
adjustments to ensure all adjustments are done correctly.
Carburetor Adjustments
The frequency at which the carburetors are synchronized or balanced is
important. Properly adjusted carburetors can greatly improve engine
performance, fuel economy, engine life, and reliability.
If you notice any of the following conditions, the carburetor may need
adjustment:
• Hard starting
• Poor idle
• Overheated pistons and cylinder walls
• Plug fouling
• Poor engine response to various throttle valve openings
81
MAINTENANCE
Carburetor
Water/Sediment Trap Service
Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting
of a hose with a plug, should be drained at least every 2000 miles (3200
km) and inspected for contamination.
WARNING! When draining the traps, fuel spillage will occur. Always work in a
well ventilated area away from anything that may cause the fuel to ignite, such
as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the
gasoline warnings found on page 56.
1. Turn the fuel tank supply valve off.
2. Position a container or shop towels to
catch the contaminated gasoline.
3. Slide the clamp away from the drain
plug and remove the drain plug from
the sediment tube.
4. Wipe residue from the plug and reinstall
it. Reposition and tighten the clamps.
Continue until all traps have been emptied.
82
Clamp
Drain
Plug
Exhaust System
MAINTENANCE
Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). To inspect, allow the engine and exhaust system to
cool completely. Open the hood and inspect the muffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.
CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.
Drive Chain Tension
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.
3. Finger tighten the adjuster
bolt 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 21 ft. lbs. (28 Nm).
5. Release the brake lever lock.
Adjuster
Bolt
Jam
Nut
83
MAINTENANCE
Brakes
n Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 47.
Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch/1.5 mm). 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 inch/1.5 mm).
Excessive Lever Travel
Hydraulic brakes are self-adjusting, but if excessive brake pad clearance
develops, bring the machine to an authorized Polaris dealer for inspection and adjustment.
Brake Components
1. Brake Caliper
2. Brake Disc
3. Brake Pad Material
(Replace when thickness is
less than 1/16I/1.5 mm).
1
2
3
84
Brakes
MAINTENANCE
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.
On some models, 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.
On all other models, frequently check the reservoir to be sure it contains
the correct amount of fluid. To add fluid, remove the master cylinder
reservoir cover. Add the recommended brake fluid to bring the level up
to the top of the fluid level mark on the inside of the reservoir.
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.
We recommend the use of Polaris DOT 4 high temperature brake fluid.
See page 111 for the part numbers of Polaris products.
NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe
up spills immediately.
Replace brake fluid at least every two years.
85
MAINTENANCE
Brakes
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 the brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16I (.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 85.
8. Reinstall the gasket and cover.
86
MAINTENANCE
Lights
Headlight Adjustment
The headlight may be adjusted for vertical aim using the following procedure.
1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall.
3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed 2I (5.1 cm) below the mark placed on the
wall.
Tip: Rider weight must be included on the seat.
5. Turn the adjustment nut (+), located inside the hood, just below the
headlamp opening. Turn the knob in or out as needed for proper
aim.
25 ft. (7.6 m)
Lamp Center Height
2I (5.1 cm)
+
87
MAINTENANCE
Lights
NOTICE: 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.
Headlight Bulb Replacement
1. Pinch the ends of the spring (1)
3
together and lift until it releases
from the spring retainer.
2. Lift the spring carefully around
2
the wire harness (2) and flip it to
the outside of the housing.
3. With the wire harness attached
to the bulb (3), withdraw the
1
bulb from the housing.
4. Grasp the bulb by its metal base
and carefully separate the bulb from the harness.
5. Hold the new bulb by its metal base and install it into the wire harness.
6. Insert the bulb into the housing. Carefully flip the spring back into
the housing, placing it around the wire harness.
7. Squeeze the spring together until it's over the spring retainer and
release.
8. Verify headlight aim. See page 87.
Taillight/Brakelight Replacement
1. Remove the screws (1) securing the
taillight housing (2).
2. Remove and replace the bulb (3).
3. Reassemble all components.
2
3
1
88
Clutch System
MAINTENANCE
Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.
NOTICE: 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 machine 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.
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 Offset
Clutch alignment offset is important for maintaining optimum performance. Please see your Polaris dealer if you experience a decrease in
performance.
Clutch Center Distance
See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.
n Drive Belt Condition
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 Belt Troubleshooting on page 116.
Tip: A worn belt will continue to function, but will not deliver maximum performance. Always carry a spare belt in case of an emergency.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.
89
MAINTENANCE
Clutch System
Drive Belt Removal
1. Stop the engine after operating in a forward motion.
NOTICE: 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.
2.
3.
4.
5.
Turn the ignition key off. Wait for the engine to stop completely.
Lock the parking brake (if equipped).
Open the hood.
Remove the clutch guard retaining pin and open the clutch
guard.
6. Rotate the driven clutch counterclockwise 1/4 turn by hand to
ensure forward engagement
before attempting to remove the
belt.
7. Locate the L-wrench in the tool
kit and install it into the open
threaded hole in the outer sheave
of the clutch. Rotate the wrench
until the sheaves open far enough
to remove the belt.
8. Firmly grasp the belt midway between the clutches and pull upward
and rearward to remove. See illustration.
90
Clutch System
MAINTENANCE
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back
the slack.
Tip: 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. Turn the driven clutch
moveable sheave clockwise
while pushing inward and forcing the belt down between the
sheaves.
3. Hold the belt down between
the sheaves and roll the bottom portion over the outer
clutch sheave. Work the belt
to the outer edge of the
sheave.
4. Rotate the L-wrench to
tighten the sheaves. Remove
the wrench and store in the
tool kit.
5. Close the clutch guard and
reinstall the retaining pin.
6. Close and secure the hood and release the parking brake.
91
MAINTENANCE
Clutch System
n Drive Belt Deflection
Measure belt deflection with both
clutches at rest and in their full
neutral position.
Place a straight edge (1) on the
belt and apply downward pressure
while measuring at point 2. This
measurement should be 1 1/4
inches (32 mm).
1
2
Drive Belt Adjustment
Belt deflection can be adjusted without removing the clutch from the
jackshaft.
1. Loosen the 7/16-inch jam nut on the belt width adjuster.
2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as
needed.
Tip: 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.
92
Clutch System
Torque Stop
If your snowmobile is
equipped with an engine
torque stop, periodically
check torque stop clearance.
With clutches in proper
alignment, the torque stop
clearance should be .010.030 inch (.25-.75 mm) from
the engine case.
Adjust if necessary, and lock
the jam nut.
MAINTENANCE
.010-.030 in.
(.25-.75 mm)
Reverse Maintenance
If your snowmobile is equipped with reverse, or if you have a reverse kit
installed, it's especially important to maintain track tension as specified
on page 96.
WARNING! Improper track tension can cause serious damage to the
snowmobile, which can result in loss of vehicle control and serious injury or
death. Always maintain the track tension as specified.
Allow the engine to reach idle speed before attempting to shift into or
out of reverse.
NOTICE: Damage will occur to chaincase or transmission if shifting is attempted
before the machine has come to a complete stop. Make sure the
snowmobile has completely stopped and the engine has returned to
idle speed before shifting gears.
93
MAINTENANCE
Chain Tension
Maintain the proper chain tension as outlined on page 83.
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
Polaris dealer. His experienced and trained service technician will keep
your machine in peak operating condition.
Tool Kit
A tool kit is included with each machine for emergency and routine
maintenance. Always keep the tool kit with the snowmobile.
94
Track
MAINTENANCE
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.
+
Track Lubrication
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 needs snow for lubrication. Excessive wear indicates
insufficient lubrication. A new rail slide can cause faster heat build-up
in limited lubrication, resulting in excessive wear.
Tip: If excessive rail slide wear occurs due to poor snow conditions, additional
wheel kits are available. See your dealer for more information.
Tip: Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.
95
MAINTENANCE
Track
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 Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only
after the track is warmed up and limber.
WARNING! Improper track tension can cause serious damage to the
snowmobile, which can result in loss of vehicle control and serious injury or
death. Always maintain the track tension as specified.
1. Turn the engine off.
2. Lift the rear of the machine 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.
4. Measure at the point where the weight is hanging.
TRACK TENSION DATA CHART
Suspension
EDGE 136
Measurement
Location
Slack
Measurement
10 lbs. (4.54 kg) 16 inches (41 cm)
ahead of rear
idler shaft
1 1/8-1 3/8 inch
(2.9-3.5 cm)
Weight
5. Check for specified slack between the wear surface of the track clip
and the plastic slider.
96
MAINTENANCE
Track
Track Tension
If the track needs adjustment:
6. Loosen the rear idler
shaft bolts.
Slack
7. Loosen the locknuts.
Measurement
8. Tighten or loosen the
track adjusting
screws to provide
equal adjustment on
both sides of the
track.
9. Repeat the measurement on the other
Track
side of the track.
Tip: Check more frequently
when the machine is
new.
Adjusting
Screw
Locknut
Shaft Bolt
S
16I (40 cm)
10 lbs. (4.54 kg)
10. Start the machine and
slowly rotate the track at least five revolutions. Let the track come
to a stop (do not apply brakes).
11. Check track alignment (see page 98) and adjust as necessary.
12. Tighten the locknuts.
13. Tighten the idler shaft bolts.
14. (n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
97
MAINTENANCE
Track
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 machine 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 the
idler shaft bolts, then
loosen the left locknut and
tighten the left adjusting
bolt. If the track runs to the
right, loosen the idler shaft
bolts, then loosen the right
locknut and tighten the
right adjusting bolt.
4. After adjustments are com+
plete, tighten the locknuts
and torque idler shaft bolts
to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
98
MAINTENANCE
Steering System
n Rail Slide Wear
For ease of inspection, all
Polaris rail slides have a
wear limit indicator groove
to indicate the minimum
permissible slide thickness.
Replace the rail slides if
they are worn to the top of
the groove at any point
along their length. Failure
to do so may result in permanent damage to the track
or rails.
Minimum
Thickness
Replace when
worn to top of
groove
Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.
EDGE IFS
+
+
+
+
+
+
99
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 1/8I to 1/4I (3-6 mm) greater
than the measurement at point Y.
Tip: If the skis are misaligned, we recommend that your dealer correct the alignment, since camber adjustment may also be affected.
EDGE IFS
X
10 in. (25.4 cm)
10 in. (25.4 cm)
Y
100
Steering System
MAINTENANCE
n Ski Skags
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.
WARNING! Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death. Replace skags as
recommended.
Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original diameter. Carbide skags must be replaced if any abnormal wear or
chipping is found.
Skag Replacement
1. Raise and support the front of the machine so the skis are approximately 6I (15.2 cm) from the ground.
2. Remove the attaching hardware and pry the skag downward.
3. Remove the rear end of the skag.
4. Remove the front end of the skag.
5. Reverse the steps to install a skag.
101
MAINTENANCE
Battery
WARNING
Battery electrolyte is poisonous. It contains acid! Serious burns can result from
contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention.
KEEP OUT OF REACH OF CHILDREN.
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk. Call physician immediately.
EYES: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, open flames, cigarettes, etc.
away. Ventilate when charging or using in closed space. Always shield eyes
when working near batteries.
Battery Fluid
A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. Maintain the fluid
level between the upper and lower
level marks.
NOTICE: Tap water contains minerals
that will damage a battery and
shorten its life. Use only distilled
water to refill your battery.
Never allow cleaning solution or
tap water to enter the battery.
Upper Mark
Lower Mark
Battery Connections
Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda
and one cup water. Rinse well with tap water and dry with clean shop
towels. Coat the terminals with dielectric grease or petroleum jelly.
102
Battery
MAINTENANCE
Battery Removal
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.
1.
2.
3.
4.
5.
Disconnect battery hold down straps.
Remove battery vent tube from battery.
Disconnect black (negative) battery cable first.
Disconnect red (positive) battery cable second.
Carefully lift the battery out of the snowmobile. Do not tip it sideways or spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.
103
MAINTENANCE
Battery
Battery Installation
WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte
as severe burns may result.
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.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder. Attach the hold down strap.
3. Install the battery vent tube. The vent tube must be free of obstructions and securely installed. Route the vent tube properly to prevent
kinks and to allow for proper drainage.
WARNING! Batteries contain gases that can explode. If the battery vent tube is
pinched or kinked, battery gases could accumulate. Always ensure that the vent
tube is free of obstructions and is securely installed as recommended.
Whenever removing or installing the battery, disconnect the negative (black)
cable first and reinstall the negative cable last to avoid the possibility of
explosion.
4.
5.
6.
7.
104
Coat the terminals with dielectric grease or petroleum jelly.
Connect and tighten the red (positive) cable first.
Connect and tighten the black (negative) cable last.
Verify that cables and vent tube are properly routed.
MAINTENANCE
Battery
Battery Storage
When your snowmobile is placed in storage for one month or more:
• Remove the battery.
• Charge it to the proper level.
• Store it in a cool dry place.
• Check and/or charge monthly.
• Have the battery tested and recharged before reinstalling it in the
vehicle.
If a battery with a low charge freezes, the cells could be damaged.
Always maintain a full charge on a stored battery. See the table below.
Charge condition
Will freeze at:
100%
-75_ F (-59_ C)
75%
-24_ F (-31_ C)
50%
0_ F (-18_ C)
25%
+13_ F (-11_ C)
0%
+18_ F (-8_ C)
105
MAINTENANCE
n Pre-Ride 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:
n Check suspension mounting bolts for tightness.
n Check rear idler wheel bolts for tightness. See page 97.
n Check rear idler adjusting bolt locknuts for tightness.
n Check front torque arm limiter strap condition.
n Check rail slide condition.
n Check track tension. See page 96.
n Lubricate all rear suspension components. See page 74.
n Check ski runner/skag condition. See page 101.
n Check ski spindle bolts for tightness.
n Check tie rod end nuts for tightness.
106
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 111 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 machine 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.
Controls and Linkage
Lubricate bushings, spindle shafts, tie rod ends and cables as outlined in
the Periodic Maintenance Table beginning on page 71.
107
MAINTENANCE
Extended Storage
Bearings
Grease the drive shaft clutch side bearing with Polaris Premium AllSeason 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. To prevent oxidation on the clutch sheaves, lubricate the sheave faces of the drive and
driven clutches with a light coat of oil or Polaris Cable Lubricant.
Tip: After storage, always use acetone or alcohol to remove the oil before reinstalling the drive belt.
Do not lubricate other clutch components, except the driven clutch shaft
bushing as outlined in the Master Repair Manual. See your dealer.
Engine and Carburetor Protection
Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage.
Whenever the machine is stored for a period of more than 60 days, the
engine must be fogged with fogging oil. Follow the engine fogging
instructions provided on the container.
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to
the fuel tank. Follow the instructions on the container, running the
engine for five minutes to get additives through the entire fuel system.
Top off with fresh fuel.
If stabilizer is not used, drain the carburetors by removing the water trap
drain plugs. See page 82.
Tip: Jet restriction caused by improper storage can cause lean conditions and
very poor slow speed driving quality.
108
Extended Storage
MAINTENANCE
Engine and Carburetor Protection
Using a fuel stabilizer and topping off the fuel tank eliminates the need
to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure
1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage.
2. Securely support the front of the snowmobile with a jack stand so
the machine is elevated and the engine is tilted rearward.
3. Remove the spark plug(s).
4. Rotate the engine slowly, watching the piston until it's at bottom
dead center (BDC), the lowest position in the cylinder. On twin cylinder models, the opposite piston will be up.
5. Pour approximately two ounces of Polaris injector oil into the spark
plug hole.
6. Wait one to two minutes and perform steps 3-5 on remaining cylinders.
7. Replace the spark plugs and lower the machine to the floor.
109
MAINTENANCE
Extended Storage
Electrical Connections
Separate electrical connector blocks and clean corrosive build-up from
connectors. Lubricate or pack connector blocks with dielectric grease
and re-connect.
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.
Battery
Always prepare and maintain the battery as outlined on page 105.
Track and Suspension
Moderate track tension should be maintained
during summer storage. The machine should be
supported off the ground to allow the track to
hang freely.
Transporting the Snowmobile
Whenever the snowmobile is transported:
1. Turn the fuel valve off. See page 57.
2. Be sure the fuel cap and oil cap are installed correctly.
3. Always tie the snowmobile to the transporting unit securely using
suitable straps.
4. Remove the ignition key to prevent loss.
110
POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
2870791
Fogging Oil (12 oz. Aerosol)
2871098
Premium 2-Cycle Engine Oil (qt.)
2871097
Premium 2-Cycle Engine Oil (gal.)
2871240
Premium 2-Cycle Engine Oil (2.5 gal.)
2871721
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)
2871722
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)
2872347
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)
Chaincase Lubricants
2873105
Synthetic Chaincase Lubricant (qt.)
2872951
Synthetic Chaincase Lubricant (12 oz.)
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 (Nyogel™)
Grease/Specialized Lubricants
Additives/Miscellaneous
2871326
Carbon Clean Plus (12 oz.)
2870652
Fuel Stabilizer (16 oz.)
2872189
DOT 4 Brake Fluid (12 oz.)
2872893
Engine Degreaser (12 oz.)
2870505
Isopropyl
2872889
Brake and Clutch Cleaner
2872890
Carb and Throttle Body Cleaner
111
TROUBLESHOOTING
Engine Troubleshooting
Unless you have experience and training in two-cycle engine repair,
see your dealer if technical problems arise.
Problem
Probable Cause Solution
Erratic engine operating RPM during
acceleration or load
variations
Drive clutch binding
• Disassemble drive clutch to inspect
shift weights for wear and free
operation. SEE YOUR DEALER.
• Clean and polish stationary shaft
hub.
Driven clutch malfunction
• Replace ramp buttons and rollers.
SEE YOUR DEALER.
• Inspect movable sheaves for excessive bushing clearance and replace
if necessary. SEE YOUR
DEALER.
Drive belt worn or
too narrow
• Replace the drive belt.
Excessive belt/
sheave clearance
• SEE YOUR DEALER.
Harsh drive clutch
engagement
Drive belt turns over
Machine fails to
move
112
Wrong belt for appli- • Replace the drive belt.
cation
Clutch alignment out
of spec
• Adjust alignment offset. SEE
YOUR DEALER.
Engine mount broken or loose
• Inspect and adjust or replace. SEE
YOUR DEALER.
Clutch jammed
• Check for twisted belt, broken
spring, sticking weights, lubrication. SEE YOUR DEALER.
Track jammed
• Foreign object may be caught or the
rail slide melted to the track clips
due to lack of lubrication.
• Track may be iced up or frozen to
the ground.
Chaincase sprocket
or chain jammed or
broken
• Chain is loose or broken or chain
tightener is loose. SEE YOUR
DEALER.
Engine Troubleshooting
TROUBLESHOOTING
Problem
Probable Cause Solution
Noise in drive system
Broken drive clutch
components
• SEE YOUR DEALER.
Bearing failure/
chaincase, jackshaft,
or front drive shaft
• SEE YOUR DEALER.
Drive belt surface
flat spots
• Inspect and replace as needed.
Drive chain loose
• Inspect and adjust (or replace).
Drive chain worn,
sprocket teeth broken
• SEE YOUR DEALER.
Worn drive belt
• Inspect and replace as needed.
Excessive belt/
sheave clearance
• SEE YOUR DEALER.
Loose torque stop
• Inspect and adjust.
Sticky clutch
• SEE YOUR DEALER.
Seized engine
• SEE YOUR DEALER. Seizure is a
result of poor lubrication, inadequate fuel supply, broken parts or
improper cooling.
Hydrostatic lock
• Fuel may have entered the crankcase while the vehicle was standing
or being transported. SEE YOUR
DEALER to correct the cause.
Drain plug(s) are located on the
lower crankcase for emergency
draining.
Engine doesn't start
(electric start models)
Wire connections
• SEE YOUR DEALER.
Engine requires
more than normal
pulls to start
Poor fuel
• Replace with fresh winter fuel.
Not enough fuel getting to engine
• SEE YOUR DEALER.
Poor low RPM performance
Engine doesn't turn
113
TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Engine turns but fails
to start
Faulty ignition
• Install new spark plug(s). If engine
still fails to start, check for spark. If
there's no spark, SEE YOUR
DEALER.
No fuel to engine
•
•
•
•
Flooded engine (too
much choke used)
• Hold throttle open, crank engine
several times (may be necessary to
change plug(s).
Poor engine compression
• Mixture is too lean. A main jet that
is too small will cause seizure
resulting in loss of power. This
indicates a major engine problem
that must be repaired before operating. SEE YOUR DEALER.
Fouled or defective
spark plug(s)
• Replace the plug(s).
Fuel filter (loss of
high RPM power)
• Check fuel filter flow. Disconnect
hose and drain 1/2 cup. Fuel flow
should be steady and encompass
the entire diameter of fuel line. If
not, replace filter.
Engine lacks power
Engine continually
backfires
114
Make sure the fuel valve is on.
Use the choke. See page 52.
Make sure fuel tank contains fuel.
Ice may be in fuel line, filter or
pump. Add isopropyl alcohol to
fuel system. On the standard
Polaris carburetor, the choke will
not function with the throttle
depressed. See second item under
Probable Cause" of Engine Continually Backfires".
Incorrect clutching
• SEE YOUR DEALER.
Carburetor and fuel
pump
• SEE YOUR DEALER.
Faulty plug(s)
• Change plug(s).
Carburetor / Fuel
System
• Dirt or ice may be in the fuel system (add deicer to non-ethanol fuel
at all times to prevent icing).
Incorrect throttle
freeplay or faulty
switch
• SEE YOUR DEALER.
EDGE 136 Suspension
TROUBLESHOOTING
Problem
Solution
Rear suspension bottoms
too easily
• Increase torsion spring preload
• Increase rear shock compression damping by turning
screw clockwise
• Increase torsion spring wire diameter (see your dealer)
• Rotate RRSS to a higher position. See page 39.
Rides too stiff in rear
• Check for binding suspension shafts and grease all
pivot points
• Decrease torsion spring preload adjustments
• Decrease rear shock compression valving by turning
screw counterclockwise)
• Check for proper track tension
• Rotate RRSS to a lower position. See page 39.
Machine darts from side
to side
• Make sure skis are aligned properly
• Make sure spindles and all steering components are
free turning
• Make sure skags are straight on skis
• Check rail slide and replace if worn
• Reduce ski pressure:
A) Increase front track spring preload
B) Reduce IFS spring preload
C) Reduce rear torsion spring preload
Front end pushes
• Check for worn skags
• Check for binding suspension shafts and grease all
pivot points
• Increase IFS spring preload by adjusting cam or
threaded adjuster
• Adjust RRSS to a higher position
Steering is heavy
• Check ski alignment
• Check skags and skis for damage
• Reduce ski pressure:
A) Increase front track spring preload
B) Reduce IFS spring preload by adjusting cam
C) Reduce rear torsion spring preload
• Make sure spindles and all steering components are
free turning (elevate machine to check)
Too much weight transfer
under acceleration
• Rotate RRSS to a higher position. See page 39.
Not enough weight transfer under acceleration
• Move RRSS to the rearward upper hole on high position. See page 39.
115
TROUBLESHOOTING
Drive Belt Troubleshooting
Belt Wear/Burn Diagnosis
Causes
Solutions
Driving at low RPM
• Drive at higher RPMs. Gear the machine down. Check
belt deflection.
Insufficient warm-up
• 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
• Do not tow in deep snow. Use fast, aggressive throttle
to engage clutch.
Riding with high RPM
and slow speed (8000
RPM/10 MPH)
• 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
• 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
• Check for carburetor and choke synchronization,
fouled plugs, debris in the carburetor(s) and water, ice
or dirt in the fuel tank or fuel line.
Loading machines onto
trailers
• 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
• Inspect clutch components. See your dealer.
Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.
ment
116
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
2. Model number
3. Dealer name
4. Date of purchase
5. Details of trouble experienced
6. Length of time and conditions of operation
7. Previous correspondence
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: 1-888-704-5290
Canada: 1-204-925-7100
117
WARRANTY
Service and Warranty Information
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.
118
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 transferable 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.
119
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.
120
Conditions and Exclusions
WARRANTY
In order to qualify for warranty, the product must have been properly set up and tested
by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle
Pre-Delivery Inspection, 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
Tracks
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Light bulbs/Sealed beam lamps
Idler wheels
Ski wear rods
Slide rails
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
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
Filters
Fuel
Sealants
Hotel fees
Towing charges
Mileage
Rentals/Loss of product use
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Meals
Shipping/ handling fees
Product pick-up/delivery
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.
121
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
• Each repair visit after the first twelve months of standard warranty coverage is subject to a $50 deductible.
• 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.
• Snowmobiles used for commercial purposes or for racing are excluded from coverage.
122
WARRANTY
Polaris Second Year Engine Service Contract
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:
• Damage due to accident, fire, explosion, theft, or other causes beyond Polaris' control.
• Damage caused by the failure of other components of the snowmobile.
• Failures caused by improper fuel or oil.
• Piston seizures, unless caused by a defective engine component.
• Failures caused due to improper adjustments.
• Failure due to unauthorized service.
• 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.
• Failure due to use of unauthorized parts or modifications.
• 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.
• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring
and other electrical components are excluded from coverage.
• Cooling system coverage is limited to the water pump assembly and components,
fan, fan bearings, temperature sensor, gasket and seals.
• Non wear related throttle body parts are covered. The fuel pump is covered.
• Clutches and related clutch parts, including but not limited to, the drive belt, are
excluded from coverage.
• Electrical components are excluded from coverage.
• Gearcases and transmissions are excluded from coverage.
123
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.
124
Exported Vehicles
WARRANTY
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 117).
125
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the Polaris standard limited warranty
for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this
emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. Polaris warrants that
the vehicle is free from defects in materials and workmanship that would cause it to fail
to meet these regulations.
The warranty period for this emissions-certified vehicle starts on the date the vehicle is
first purchased and continues for a period of 200 hours of engine operation, 4000 kilometers (2485 miles) of vehicle travel, or 30 calendar months from the date of purchase,
whichever comes first.
This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions, and it covers components of systems whose only purpose is to
control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not
cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust emissions:
• Aftertreatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
The following parts are considered emission-related components for evaporative emissions:
• Fuel Tank
• Vacuum Control Diaphragms*
• Fuel Cap
• Control Cables*
• Fuel Line
• Control Linkages*
• Fuel Line Fittings
• Purge Valves
• Clamps*
• Vapor Hoses
• Pressure Relief Valves*
• Liquid/Vapor Separator
• Control Valves*
• Carbon Canister
• Control Solenoids*
• Canister Mounting Brackets
• Electronic Controls*
• Carburetor Purge Port Connector
*As related to the evaporative emission control system.
126
WARRANTY
U.S.A. EPA Emissions Limited Warranty
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. 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 when the vehicle 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 may deny warranty claims for failures that have been caused by
the owner’s or operator’s improper maintenance or use, by accidents for which Polaris
has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle.
Polaris also recommends that you use only Pure Polaris parts. 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.
If you have any questions regarding your warranty rights and responsibilities, please
contact the Polaris Warranty Department at 1-888-704-5290.
127
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)
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
128
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
129
MAINTENANCE LOG
DATE
130
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
131
INDEX
A
C
Accessories . . . . . . . . . . . . . . . . . . . 44
Air Box Warning . . . . . . . . . . . . . . . 22
Air Pollution . . . . . . . . . . . . . . . . . . . 5
Altitude Setting . . . . . . . . . . . . . . . . 67
Avalanches. . . . . . . . . . . . . . . . . . . . 14
Cold Weather Drive-Away . . . . . . . . 18
Controls and Linkage. . . . . . . . . . . . 107
Coupling, Front To Rear . . . . . . . . . . 37
Coupling, Rear To Front . . . . . . . . . . 38
Coupling, Suspension . . . . . . . . . 37-38
Customer Service. . . . . . . . . . . . . . . 117
B
Backrest . . . . . . . . . . . . . . . . . . . . . . 28
Battery . . . . . . . . . . . . . . . . . . . 102-105
Battery Connections. . . . . . . . . . . . 102
Battery Fluid . . . . . . . . . . . . . . . . . 102
Battery Installation. . . . . . . . . . . . . 104
Battery Storage . . . . . . . . . . . 105, 110
Bearings . . . . . . . . . . . . . . . . . . . . . 108
Bleeding the Brake System . . . . . . . 86
Brake Components. . . . . . . . . . . . . . 84
Brake Fluid . . . . . . . . . . . . . . . . . . . 85
Brake Inspection . . . . . . . . . . . . . . . 84
Brake Inspection, Hydraulic . . . . . . 84
Brake Lever Feel . . . . . . . . . . . . . . . 47
Brake Lever Travel, Hydraulic . . . . 47
Brake System Bleeding . . . . . . . . . . 86
Brakelight Replacement. . . . . . . . . . 88
Brakes . . . . . . . . . . . . . . . . . . 47, 84-86
C
Carbide Skags . . . . . . . . . . . . . . . . . 42
Carburetion . . . . . . . . . . . . . . . . . 60-61
Carburetor . . . . . . . . . . . . . . . . . . 81-82
Carburetor Adjustments. . . . . . . . . . 81
Carburetor Protection. . . . . . . . 108-109
Cargo Overload . . . . . . . . . . . . . . . . 11
Chain Tension . . . . . . . . . . . . . . . . . 94
Chaincase Oil. . . . . . . . . . . . . . . . . . 76
Choke. . . . . . . . . . . . . . . . . . . . . . . . 52
Choke Cable Lubrication. . . . . . . . . 75
Choke Lubrication . . . . . . . . . . . . . . 75
Cleaning and Preservation . . . . . . . 107
Clutch Alignment Offset . . . . . . . . . 89
Clutch and Drive System . . . . . . . . 108
Clutch Center Distance . . . . . . . . . . 89
Clutch Cover Warning. . . . . . . . . . . 22
Clutch Guard . . . . . . . . . . . . . . . . . . 18
Clutch Safety . . . . . . . . . . . . . . . . . . 18
Clutch System . . . . . . . . . . . . . . . 89-93
132
D
Deicers . . . . . . . . . . . . . . . . . . . . . . . . 58
Disabled Operators . . . . . . . . . . . . . . 11
Drive Belt . . . . . . . . . . . . . . . . . . . . . 17
Drive Belt Adjustment. . . . . . . . . . . . 92
Drive Belt Condition . . . . . . . . . . . . . 89
Drive Belt Deflection. . . . . . . . . . . . . 92
Drive Belt Installation . . . . . . . . . . . . 91
Drive Belt Removal . . . . . . . . . . . . . . 90
Drive Chain Tension . . . . . . . . . . . . . 83
Driver Awareness . . . . . . . . . . . . . . . 13
Driveshaft Bearing Lubrication . . . . . 75
Driving Downhill. . . . . . . . . . . . . . . . 16
Driving in Hilly Terrain. . . . . . . . . . . 17
Driving on Slippery Surfaces . . . . . . 15
Driving Responsibly . . . . . . . . . . . . . 20
E
Electrical Connections. . . . . . . . . . . 110
Emission Control Information . . . . . . 69
Emissions Limited Warranty . . 126-127
Engine Break-In. . . . . . . . . . . . . . 53-54
Engine Protection . . . . . . . . . . 108-109
Engine Safety. . . . . . . . . . . . . . . . . . . . 8
Engine Stop Switch . . . . . . . . . . . . . . 62
Environment . . . . . . . . . . . . . . . . . . . . 5
Exhaust . . . . . . . . . . . . . . . . . . . . . . . 56
Exhaust System . . . . . . . . . . . . . . . . . 83
F
Filters, Intake . . . . . . . . . . . . . . . . . . . 79
FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel . . . . . . . . . . . . . . . . . . . . . . . 56-58
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 80
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 80
Fuel Recommendations . . . . . . . . . . . 57
Fuel Reserve . . . . . . . . . . . . . . . . . . . 58
Fuel System Deicers . . . . . . . . . . . . . 58
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 57
INDEX
H
Handlebar Adjustment . . . . . . . . . . .
Headlight Adjustment . . . . . . . . . . . .
Headlight Bulb Replacement . . . . . .
Hood Latches . . . . . . . . . . . . . . . . . .
P
40
87
88
50
I
Ice and Snow Build-up . . . . . . . . . . .
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . .
IFS Adjustments . . . . . . . . . . . . . . . .
IFS Components . . . . . . . . . . . . . . . .
Inadequate Snow Conditions . . . . . .
Intake Filters . . . . . . . . . . . . . . . . . . .
Intake Silencer . . . . . . . . . . . . . . . . .
15
29
29
29
19
79
17
J
Jetting Guidelines . . . . . . . . . . . . . . . 61
L
Lever
Brake . . . . . . . . . . . . . . . . . . . . . 26
Brake, Excessive Travel . . . . . . 84
Brake, Hydraulic . . . . . . . . . . . . 47
Brake, Spongy. . . . . . . . . . . . . . 86
Throttle . . . . . . . . . . . . . . . . 46, 63
Lever Travel, Brake . . . . . . . . . . . . . 84
Lights . . . . . . . . . . . . . . . . . . . . . 87-88
Low Oil Indicator Light . . . . . . . . . . 59
Lubrication . . . . . . . . . . . . . . . . . 74- 76
M
Maintenance . . . . . . . . . . . . . . . . . . . 18
Maintenance Interval Table . . . . 71-73
Maintenance Log . . . . . . . . . . 128-131
Maintenance Program . . . . . . . . . . . . 70
Maneuverability . . . . . . . . . . . . . . . . 18
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 5
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 80
Oil Injection System . . . . . . . . . . . . . 54
Oil Level . . . . . . . . . . . . . . . . . . . . . . 59
Oil Recommendations. . . . . . . . . . . . 54
Operation Warning . . . . . . . . . . . . . . 25
Operator Safety . . . . . . . . . . . . . . . 6-21
Parking Brake Lever Lock . . . . . . . . 48
Passenger Warning . . . . . . . . . . . . . . 23
Polaris Products . . . . . . . . . . . . . . . 111
Preload, Front Shock Spring. . . . . . . 31
Pre-Ride Checklist . . . . . . . . . . . . . . 45
Pre-Ride Suspension Inspection . . . 106
R
Rail Slide Wear. . . . . . . . . . . . . . . . . 99
Recoil Rope . . . . . . . . . . . . . . . . . . . 50
Registration, Warranty . . . . . . . . . . 119
Reverse Maintenance . . . . . . . . . . . . 93
Reverse Warning, Electronic . . . . . . 24
Reverse, Electronic . . . . . . . . . . . 65-67
Rider Capacity . . . . . . . . . . . . . . . . . 11
Riding Apparel . . . . . . . . . . . . . . . . . . 9
Riding Position . . . . . . . . . . . . . . . . . 10
RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 38
S
Safety Decals . . . . . . . . . . . . . . . 22-25
Safety Symbols . . . . . . . . . . . . . . . . . . 6
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Scissor Stop, Front Rear . . . . . . . . . . 37
Scissor Stop, Rear Rear . . . . . . . . . . 38
Shock Components . . . . . . . . . . . . . . 30
Shock, Rear, Indy Select. . . . . . . . . . 36
Signal Words . . . . . . . . . . . . . . . . . . . 6
Ski Alignment . . . . . . . . . . . . . . . . . 100
Ski Skags . . . . . . . . . . . . . . . . . . . . 101
Slide Rail and Track Cooling . . . . . . 56
Snow Conditions. . . . . . . . . . . . . . . . 19
Spark Plug Condition . . . . . . . . . . . . 77
Spark Plug Removal . . . . . . . . . . . . . 78
Spark Plugs . . . . . . . . . . . . . . . . . 77-78
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 12
Spring Preload, Front Shock. . . . . . . 31
Spring Preload, Rear . . . . . . . . . . . . . 34
Springs, Front . . . . . . . . . . . . . . . . . . 31
Starting the Engine . . . . . . . . . . . 52-53
Steering Inspection/Adjustment . . . . 99
Steering Lubrication . . . . . . . . . . . . . 74
Steering System . . . . . . . . . 49, 99-101
Stopping, Emergency . . . . . . . . . . . . 64
Storage, Daily . . . . . . . . . . . . . . . . . . 68
Storage, Extended . . . . . . . . . . . 10-110
Studs . . . . . . . . . . . . . . . . . . . . . . . . . 41
133
INDEX
S
T
Survival Preparation . . . . . . . . . . . . 10
Suspension Adjustments . . . . . . . 34-39
Suspension Adjustments, Front . . 29-31
Suspension Adjustments, Rear . . 32-33
Suspension Coupling . . . . . . . . . . 37-38
Suspension Inspection, Pre-Ride . . 106
Suspension Lubrication . . . . . . . . 74-75
Suspension Performance Tips . . . . . 33
Switches
Engine Stop . . . . . . . . . 26, 51, 62
Handwarmer . . . . . . . . . . . . . . 26
Headlight Dimmer . . . . . . . . . . 26
Ignition. . . . . . . . . . . . . . . . 26, 51
Throttle Safety . . . . . . . . . . 46, 62
Thumbwarmer . . . . . . . . . . . . . 26
Track . . . . . . . . . . . . . . . . . . . . . . 95-98
Track, Damage. . . . . . . . . . . . . . . . . . 49
Track, Tension . . . . . . . . . . . . . . . . . . 96
Track Alignment . . . . . . . . . . . . . . . . 98
Track Care for Storage . . . . . . . . . . 110
Track Cooling . . . . . . . . . . . . . . . . . . 56
Track Inspection . . . . . . . . . . . . . . . . 95
Track Lubrication . . . . . . . . . . . . . . . 95
Track Safety. . . . . . . . . . . . . . . . . . . . . 8
Track Tension . . . . . . . . . . . . . . . . . . 33
Track Warm-Up. . . . . . . . . . . . . . . . . 55
Track Warning. . . . . . . . . . . . . . . . . . 23
Traction Products. . . . . . . . . . . . . 41-43
Transporting the Snowmobile . . . . . 110
Trap, Carburetor . . . . . . . . . . . . . . . . 82
Troubleshooting, Drive Belt . . . . . . 116
Troubleshooting, Engine . . . . . 112-114
Troubleshooting, Suspension. . . . . . 115
Tune-Up. . . . . . . . . . . . . . . . . . . . . . . 94
T
Taillight/Brakelight Replacement . . 88
Tension, Rear Spring . . . . . . . . . . . . 35
Throttle Cable Lubrication . . . . . . . 75
Throttle Lever . . . . . . . . . . . . . . 46, 63
Throttle Safety Switch . . . . . . . . 46, 62
Tool Kit . . . . . . . . . . . . . . . . . . . . . . 94
Torque Stop . . . . . . . . . . . . . . . . . . . 93
Torsion Springs . . . . . . . . . . . . . . . . 37
Towing. . . . . . . . . . . . . . . . . . . . . . . 68
134
V
Vehicle Identification Numbers. . . . . . 4
W
Water Pump Belt . . . . . . . . . . . . . . . . 79
Water/Sediment Trap Service . . . . . . 82
Wear Strips . . . . . . . . . . . . . . . . . . . . 43
Weight Transfer. . . . . . . . . . . . . . . . . 39
Windchill . . . . . . . . . . . . . . . . . . . . . . 21
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