Alienware D01M Personal Computer User Manual

550 IQ Shift
550 IQ 136
550 IQ LXT
Snowmobile Owner's Manual
for Maintenance and Safety
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.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
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. 9923893 Rev 01
Printed in USA
*9923893
*
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the 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®
• Low emission vehicles (LEVs)
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.
1
The following are registered trademarks of POLARIS Industries Inc.:
POLARIS®
THE WAY OUT®
IQ®
IQ SHIFT®
PERC®
Copyright 2012 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
Owner's Manual P/N 9923893
2013 550 IQ SHIFT / 550 IQ 136 / 550 IQ LXT
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 28
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 40
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 98
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 119
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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.
Tunnel VIN
Vehicle Model Number: ___________________________________________________
Tunnel VIN (right side of the tunnel): _________________________________________
Engine Serial Number (on recoil housing): ____________________________________
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.
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 indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
6
SAFETY
Operator Safety
Follow the recommended maintenance program beginning on page 62
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.
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.
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.
8
SAFETY
Operator Safety
Riding Apparel
Be prepared, be warm and be comfortable when riding. Be aware of the
weather forecast, especially the windchill, and dress accordingly. See the
chart on page 20.
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
of a circle surrounding the letter E, followed by the
E4
distinguishing number of the country which has
051039
granted approval. The approval number and serial
0006.31
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
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:
•
•
•
•
•
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
Tool Kit
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. If equipped, do not exceed carrier and rack weight limits, and do
not allow a passenger to sit on the cargo carrier.
10
SAFETY
Operator Safety
Rider Capacity
Driving 1-Up - Some POLARIS snowmobiles are designed for a single
rider only. A decal on the console of these models indicates single rider
operation. Never carry a passenger on a single-rider snowmobile.
Driving 2-Up - Some POLARIS snowmobiles are designed for up to
two riders. A decal on the console of these models indicates that the
vehicle is designed for one operator and one passenger only.
WARNING! Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed for stopping.
Make sure the passenger remains seated behind the driver, facing forward, with
both feet placed firmly on the running boards. Slow down and avoid “jumping”
your snowmobile.
Snowmobiles designed for two riders should never be operated with
more than two people on board. When traveling with a passenger, it’s
the driver’s responsibility to operate the snowmobile safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are necessary
for stopping.
Excessive Speed
WARNING! High speed driving, especially at night, could result in serious injury
or death. Always reduce speed when driving at night or in inclement weather.
Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) 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.
11
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. Always check with local residents or authorities for general
information on conditions when traveling on lakes and streams that are
strange to you. Before riding your snowmobile on a frozen body of
water, be sure the ice is thick enough to support the snowmobile and its
operator, as well as the force created by a moving vehicle. You may
drown if you and the snowmobile break through the ice.
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.
R
12
R
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 either the
American Avalanche Association online at www.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at
www.avalanche.org.
13
SAFETY
Operator Safety
Ice and Snow Build-up
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.
Driving on Slippery Surfaces
WARNING! Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hardpacked snow reduces steering and braking control, which may result in loss of
control and serious injury or death. Slow down and use extra caution when
operating on slippery surfaces.
14
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.
15
SAFETY
Operator 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.
16
SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from
ice and snow before attempting to drive. Apply the throttle with enough
authority to put the snowmobile into motion, but always operate within
safety limits and, on 2-up machines, with respect for a passenger.
Maneuverability
While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of
your body weight. Maneuverability will change for lighter operators or
snowmobiles designed to carry a load or a passenger.
Maintenance
Follow the recommended maintenance program beginning on page 62
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.
17
SAFETY
Operator Safety
Inadequate Snow Conditions
WARNING! Do not drive for prolonged periods on blacktop, gravel, or ice.
Doing so could cause irreversible track damage and lead to serious injury.
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.
NOTICE: When operating on icy surfaces or hard-packed snow, avoid overheating the slide rail and track. Lack of lubrication and cooling will cause
overheating of the slide rail and track, resulting in premature wear and
failure. If frequently operating in low cooling conditions, see your
dealer for an optional wheel kit that will reduce the wear from overheating.
18
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 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.
19
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
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.
WIND CHILL CHART (°C)
Wind
Speed
in
Km/h
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.
20
10 min.
5 min.
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.
21
SAFETY
Safety Decals and Locations
Track Warning
The track warning decal is on the
rear of the tunnel:
Stay clear of track. Do not sit
on seat back. Entanglement
with the track or a fall from seat
back may result in severe
injury or death.
X
“No Passenger” Warning
Snowmobiles designed for singlerider use have a warning decal on
the lower right console.
WARNING
This vehicle is designed for
operator only.
“NO PASSENGER”
Passenger Warning
Snowmobiles designed for an operator and one passenger have a
warning decal on the lower right
console.
WARNING
This vehicle is designed for
operator and “ONE” passenger
only.
22
X
SAFETY
Safety Decals and Locations
Reverse Warning
X
The reverse warning decal is located
on the upper console:
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.
NOTE: 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.
Operation Warning
The operation warning decal is
located on the lower console. See
page 24 for the text.
X
23
SAFETY
Safety Decals and Locations
Operation 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.
24
FEATURES
4
3
5
2
6
7
1
8
14
9
10
11
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
13
Hood
17
Headlight
16
Windshield
18
15
Handlebar
19
Seat
Taillights
Rear Bumper
Snow Flap
Console Storage Compartment
(if equipped)
Suspension
Track
Skis
Nosepan
Front Bumper (do not use for pulling or dragging the snowmobile)
Passenger Grab Handle (LXT)
Passenger Seat (LXT)
Passenger Backrest (LXT Accessory)
Cargo Bag (LXT Accessory)
Cargo Rack (LXT Accessory)
25
FEATURES
2
1
6
3
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Fuel Filler Cap/Dipstick
Recoil Starter Handle
Reverse Indicator
Headlight Adjuster
Speedometer
Engine Stop Switch
Choke Lever
Ignition Switch
Brake Lever
Parking Brake
Handlebar Grip Warmer Switch
Thumbwarmer Switch
Electronic Reverse Button
Headlight Dimmer Switch
Throttle Control
7
8
5
9
10
11
14
12
13
15
26
FEATURES
Cargo Bag
The accessory cargo bag is secured to the
rear of the tunnel with straps.
Cargo Bag
The maximum weight capacity for the
cargo area is 30 lbs. (14 kg). Always
secure cargo before operating. Do not
exceed the weight limit. Do not allow a
passenger to sit on the cargo area.
Adjustable Headlights
Adjust the headlight beam by moving
the adjuster to the left or right.
Passenger Grab Handle
If equipped, the passenger grab handles
can be adjusted for rider preference.
1. Remove the hardware securing the
grab handles to the grab handle
tube.
2. Reposition the grab handles to one
of the three available positions and
reinstall the hardware securely.
Adjustment Positions
27
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. A-arms
1
2
3
IFS Adjustment Options
• Front shock spring preload
• Optional springs
4
28
THE PERFECT FIT
Front Suspension Adjustments
Shock Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing spring
preload will decrease ski-to-ground pressure. When adjusting, be sure the springs
on both the left and right sides of the
machine are at the same adjustment.
To change front shock spring preload,
grasp the spring and rotate it.
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch of preload beyond the factory settings, and
ensure that both sides are adjusted the
same. When decreasing preload, make
High
Low
sure at least two turns of preload are holdPreload
Preload
ing the spring between the retainer on the
top of the shock and the threaded spring
preload adjuster nut on the shock body.
Failure to do so could cause the retainer to fall off when the suspension
is fully extended.
Tip: Not all models have shocks with thread adjustable spring preload. See your
dealer for more information.
NOTICE: On some models equipped with a plastic adjuster nut, the nut will
break if it is unscrewed from the threaded body. Do not force the nut if
resistance suddenly increases while you’re turning it.
29
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.
Refer to the suspension setup label on your snowmobile, or 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.
30
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. Refer
to the Pre-Ride Suspension Inspection on page 45.
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 86.
31
THE PERFECT FIT
Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the rear suspension torsion
spring preload, measure the distance
between the ground and rear bumper. This
is measurement X.
Take 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
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). If the measured sag is
incorrect, adjust the FRA position and/or
rear torsion spring preload.
Suspension Recommended Sag
Y
Adjustment
See
Page
IQ (121)
4-5 inches (10-13 cm)
Torsion Spring
Preload
33
IQ Comfort
(136)
4-5 inches (10-13 cm)
Torsion Spring
Preload
33
Tip: This is only an initial setup, and final spring preload may vary based on rider
preference and riding conditions. Accessory springs with a higher load rating are available for some models. Please see your dealer for availability.
32
THE PERFECT FIT
IQ Rear Suspension Adjustments
Torsion Spring Preload
To adjust rear torsion spring preload, rotate the three-position cam using
the engine spark plug tool. Adjustment is easiest when the cam is
rotated from low to medium, and then to high. Rotating directly from
low to high will require significantly more effort.
Different rate torsion springs are available if a firmer ride is desired. See
your dealer for more information.
Soft
Medium
Firm
Limiter Strap Position (Ski Pressure)
Ski pressure is set at the factory to
deliver the optimum balance
between ride and handling. If a
rider prefers more ski pressure for
improved steering performance,
adjustments can be made to the
Upper
front limiter straps. Tighten the
Nuts
straps to increase ski pressure.
Loosen the straps to reduce ski
pressure.
1. Remove the nuts and flat
washers from the upper limiter
straps.
2. Relocate the straps to the desired position.
3. Reinstall the nuts and washers. Tighten securely.
33
THE PERFECT FIT
IQ Rear Suspension Adjustments
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.
34
THE PERFECT FIT
IQ 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.
Rear Rear Scissor Stop (RRSS) - Attributes
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
• Increased load carrying capacity (2-up)
35
THE PERFECT FIT
IQ 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, rotate the RRSS
to a lower position.
HIGH
LOW
LOW
MEDIUM
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.
FRSS
36
RRSS
THE PERFECT FIT
Traction Products
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 93.
If your snowmobile has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.
Inspect skags frequently. Worn skags may reduce steering and braking
control on hard-packed snow and ice. Replace worn 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.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used.
Install the appropriate wear strip kit. See your dealer.
Wear strips are designed for a specific stud length. See your dealer's
studding chart for recommended traction accessories.
NOTICE: Whenever wear strips are relocated, be sure there's adequate stud
clearance to the tunnel. Lack of clearance may result in damage to
tunnel.
37
THE PERFECT FIT
Handlebar Adjustments
When making handlebar adjustments, always be sure the handlebars,
brake lever and throttle lever operate smoothly and do not contact the
fuel tank, windshield or any other part of the vehicle when the handlebars are turned fully to the left or right.
Upper
Bolts
Lower
Bolts
Handlebar Position
Follow these steps to adjust handlebar position.
1. Remove the handlebar cover.
2. Loosen the four upper and four lower adjuster block bolts.
3. Adjust the handlebar to the desired position.
4. Torque the front bolts first, then torque the rear bolts. Torque the
bolts to 15-17 ft. lbs. (20-23 Nm).
5. Reinstall the handlebar cover.
38
THE PERFECT FIT
Handlebar Adjustments
Handlebar Angle
Follow these steps to adjust handlebar angle at the handlebar block.
1. Remove the handlebar cover.
2. Loosen the four upper adjuster block bolts.
3. Adjust the handlebar to the desired angle.
4. Torque the bolts to 15-17 ft. lbs. (20-23 Nm).
5. Reinstall the handlebar cover.
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.
39
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the referenced pages.
Item
Drive Belt Condition
See Page
83, 85
Steering System
44
Recoil Rope
45
Cooling System Seal
73
Parking Brake Lock/Brake Lever/Brake System
42, 43, 77
Auxiliary Shut-Off Switch (Engine Stop Switch)
46
Ignition Switch
46
Taillight/Brakelight/Headlight
46
Suspension Mounting Bolts
45
Skags (Wear Bars)
37, 93
Ski Spindle Bolts
45
Hood Straps/Latches
45
Throttle Lever/Safety Switch
56, 57
Rear Wheel Idler Bolts
89
Tether Switch/Strap (accessory)
46
Track Alignment/Condition
44, 90
Rail Slide Condition
94
Chaincase Oil Level
68
Injection Oil Level
53
40
PRE-RIDE INSPECTIONS
Before Starting the Engine
WARNING! Worn, damaged, or malfunctioning components may cause serious
injury or death. Before starting the engine, check all components to be sure of
proper operation.
Read and Understand Your Owner's Manual
Read the Owner's Manual completely and refer to it often. The manual
is your guide to safe and enjoyable snowmobiling experience.
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.
Throttle Safety Switch
Test the throttle safety switch system before the machine is operated.
See page 56.
41
PRE-RIDE INSPECTIONS
Before Starting the Engine
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 1/2” (1.3 cm).
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. Refer
to the brake bleeding information on page 79 or see
your dealer for service.
1/2” (1.3 cm)
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 78.
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.
42
PRE-RIDE INSPECTIONS
Before Starting the Engine
Parking Brake Lever Lock
Use the parking 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
3
4
2. Parking Brake Lever
1
2
Lock
3. Master Cylinder Reservoir/ Cover
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze
the brake lever tightly and
push forward on the lock.
Hold the lock forward while
releasing the brake lever.
Tip: 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 will illuminate if the parking brake lever lock is set
while the engine is running. It will also illuminate 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. The lock will return
to the unlock 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.
43
PRE-RIDE INSPECTIONS
Before Starting the Engine
Steering System
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.
Track
WARNING! Operating the snowmobile with a damaged track increases the
possibility of track failure, which could cause loss of control resulting in serious
injury or death. Always inspect the track for damage before using the vehicle.
Use of traction products such as studs increases the possibility of track
damage and/or failure. Driving at high speeds for extended periods of
time in marginal lubrication could severely damage track rods, break
track edges, and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy
trails, and no-snow conditions.
Tip: Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.
44
PRE-RIDE INSPECTIONS
Before Starting the Engine
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.
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.
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.
Item
Check
Page
Suspension mounting bolts
Tightness
--
Rear idler wheel bolts
Tightness
89
Rear idler adjusting bolt locknuts
Tightness
--
Torque arm bolts
Tightness
--
Carrier and bogie wheel bolts
Tightness
--
Front torque arm limiter strap
Condition
--
Rail slide
Condition
94
Tension
88
Track
All rear suspension components
Lubrication
66
Ski runner/skag
Condition
93
Ski spindle bolts
Tightness
--
Tie rod end nuts
Tightness
--
45
PRE-RIDE INSPECTIONS
Start the Engine and Check
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting
the Engine beginning on page 41.
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.
Ignition Switch
Make sure the engine stops when the ignition switch is turned to OFF.
Tether Switch (if equipped)
If your machine has a tether switch, remove the tether from the switch to
make sure the engine stops immediately.
Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
Mirrors (if equipped)
Adjust the mirrors so they can be used to their full advantage.
Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the machine.
46
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 52.
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. Do not depress the
throttle until the engine
starts.
CHOKE POSITIONS
OFF
1/2 CHOKE
FULL CHOKE
CAUTION! To avoid injury and/or engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.
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.
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.
6. If not equipped with electric start, grasp the starter 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.
47
OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 56 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 (accessory) Interrupts ignition circuit
All
Break-In Period
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of fuel with one pint of POLARIS injection 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.
48
OPERATION
Break-In Period
Oil Injection System
Always check and fill the oil tank when refueling. See page 53.
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 POLARIS Premium 2Cycle Semi-Synthetic Oil or VES Gold Plus 2-Cycle Oil for this engine.
See page 102 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.
Drive Belt Break-In
The break-in period for a new drive belt is 30 miles (48 km). During this
time, vary the throttle position under 50% and limit full throttle use.
New drive belts should be washed with warm, soapy water and allowed
to air dry prior to use.
Always take time to warm up the belt and driveline prior to operating
the snowmobile. Free the track and skis from the ground before engaging throttle.
49
OPERATION
Track Warm-Up
WARNING! A loose track or flying debris could cause serious injury or death.
Stand clear of the front of the machine and the moving track. Never hold the
snowmobile up or stand behind it while warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Use a
stable rear support.
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” (10 cm) off
the ground.
2. Start the engine and allow it to warm up two to three minutes.
3. Depress the throttle abruptly and allow the track to rotate several
revolutions.
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.
Slide Rail and Track Cooling
Inadequate cooling and lubrication will lead to overheating of the slide
rail and track, resulting in premature wear and failure.
1. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.
2. Avoid operating on ice, hard-packed surfaces or roads.
50
OPERATION
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.
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.
51
OPERATION
Fuel
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.
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 102 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.
Fuel Valve
The fuel valve is located between the
oil bottle and engine intake duct.
Turn the fuel valve off whenever the
snowmobile is stored or parked.
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.
52
OFF
ON
OPERATION
Oil
Low Oil Indicator Light
The low oil indicator light may flicker at times due to oil movement in
the bottle, but when the light comes on and remains on, add the recommended oil before further operation. See page 49 for oil recommendations.
Visually check for oil in the bottle. The engine may be operated as long
as oil is visible in the oil tank. If oil is not visible, continued operation
may cause serious engine damage.
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.
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.
Always maintain a visible level of oil in the tank. If oil is not visible,
continued operation may cause serious engine damage. See page 49 for
oil recommendations.
The POLARIS oil cap on the oil bottle is vented to allow proper oil
flow. See your POLARIS dealer for recommended replacement parts.
53
OPERATION
Carburetion
NOTICE: Making non-recommended adjustments could result in vehicle or
engine damage as well as denial of warranty claims. We recommend
that all carburetor adjustments be performed by your POLARIS
dealer.
Proper carburetor adjustment is critical. 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.
54
OPERATION
Carburetion
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 of -15° to +5° F. (-26° to -15° 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 74 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 the specifications section of this manual. See page 98.
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.
55
OPERATION
Engine Stop Switch
Push down on the engine
stop switch (X) to ground
out the ignition and stop
the engine quickly. Pull
the switch up to the ON
position to allow restarting.
X
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.
56
OPERATION
Throttle Lever
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.
57
OPERATION
Electronic Reverse (PERC)
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 59. Always make sure the vehicle is
stopped and the engine is running at idle before shifting to reverse
Tip: The engine will activate a misfire mode and begin to stutter after 45 seconds in reverse. This feature protects the engine from overheating and will
reset when it is shifted into forward or when the engine is stopped and
restarted.
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.
58
OPERATION
Electronic Reverse (PERC)
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 machine is in reverse.
4. Apply the throttle slowly to make sure the machine 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.
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Push the yellow reverse button for one second and release. The
engine will slow and and begin to rotate forward. The light on the
instrument panel will shut off.
3. Apply the throttle slowly to make sure the machine 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.
59
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.
60
MAINTENANCE
Emission Control Information
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 U.S.A EPA Emissions Limited Warranty beginning on
page 117, 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.
Non-ionizing Radiation
This vehicle emits some electromagnetic energy. People with active or
non-active implantable medical devices (such as heart monitoring or
controlling devices) should review the limitations of their device and the
applicable electromagnetic standards and directives that apply to this
vehicle.
61
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 119.
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.
62
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)
82
I
Drive Belt Condition
83
I
I
I
Clutches (disassemble)
82
C
C
C
I
Belt Tension
--
I
I
I
I
Clutch Sheaves
82
I
I
I
I
I
ENGINE
Engine Mounts
--
I
I
I
Engine Mounting Plate
--
I
I
I
Engine Torque Stop
85
I
I
I
Cylinder Head Bolts
--
I
I
I
Cylinder Base Nuts
--
I
I
I
Ignition Timing BTDC
--
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
Recoil Rope
--
Spark Plug Condition
71
Exhaust Pipe
73
Exhaust Retaining
Springs
73
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
63
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
77
I
I
I
I
Brake Disc
--
I
I
I
I
Parking Brake
43
I
I
I
Brake System
42, 77
Brake Fluid
I
I
78
I
FUEL MANAGEMENT
Pilot Air Screws
--
I
I
I
Carburetor
(synchronize)
74
I
I
I
I
I
I
I
I
I
Idle RPM
--
Throttle Lever
57
Oil Pump Lever
(synchronize)
--
I
I
I
Throttle Cable
67
L
L
L
Choke Cable
67
L
L
L
Choke
67
I
I
I
Vent Lines
--
I
I
I
I
Fuel Lines
73
I
I
I
I
Fuel Filter
73
R
R
Oil Filter
72
R
R
Oil Lines
72
I
I
I
Air Box
--
I
I
I
I
Drain and Water Traps
75
I
I
I
Auxiliary Shut-Off
Switch
56
I
I
I
I
I
Throttle Safety Switch
56
I
I
I
I
I
Ignition Switch
--
I
I
I
I
I
Taillight
46
I
I
I
I
I
Brakelight
46
I
I
I
I
I
Headlight
46
I
I
I
I
I
I
I
I
I
ELECTRICAL
64
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
I
I
I
I
I
I
I
CHASSIS
Ski Toe Alignment
--
Suspension Mounting
Bolts
--
Steering Fasteners
--
I
I
I
I
C
Rear Suspension Fasteners
--
I
I
I
I
I
I
Suspension Shock Oil
--
I
I
I
I
Cooling System
73
I
I
I
I
Drive Shaft Bearing
67
L
L
L
I
Jackshaft Bearings
96
L
L
L
I
Skags (Wear Bars)
93
I
I
I
I
I
Ski Saddle/Spindle
Bolts
--
I
I
I
I
I
Steering Arm(s)
--
Drive Chain Tension
76
I
I
I
I
I
I
Hood Latches
45
I
I
I
I
I
Rear Wheel Idler Bolts
89
I
I
I
I
I
Idler Bolt Jam Nut
89
I
I
I
I
Rear Suspension Pivot
Shafts
66
L
L
Camber Alignment
--
I
I
I
Handlebar Centering
--
Tether Switch and Strap
46
I
I
I
I
I
Track Alignment
90
I
I
I
I
I
Track Tension
88
I
I
I
I
I
Front Limiter Strap
--
I
I
I
I
Rail Slide Condition
94
Chaincase Oil
68
I
L
I
I
I
I
I
I
R
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
65
MAINTENANCE
Lubrication
Front Suspension
The front suspension does not require lubrication.
Rear Suspension
Lubricate the suspension pivot shafts with POLARIS Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 62 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).
Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer.
IQ Rear Suspension (121)
X
X
X
X
IQ Comfort Rear Suspension (136)
X
X
X
X
66
MAINTENANCE
Lubrication
Driveshaft Bearing
Inject grease into the fitting on the
speedometer sensor housing until
grease purges from the seal on the
inside of the tunnel. This should
take approximately two pumps. Do
not use more than four pumps.
X
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.
X
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.
X
67
MAINTENANCE
Lubrication
Chaincase Oil
Check the chaincase oil level at the
intervals outlined in the maintenance
charts beginning on page 62. The sight
glass (1) is located on the lower rear of
the chaincase. Maintain the oil level at
or slightly below the center of the sight
glass (2). Change the chaincase oil after
the first 500 miles (800 km), then every
1000 miles (1600 km) or seasonally.
POLARIS recommends the use of
POLARIS Synthetic Chaincase Lube.
See page 102 for the part numbers of
POLARIS products.
Oil Check
1. Position the vehicle on a level surface.
2. View the oil level at the sight glass.
3. Remove the fill plug (3) and add the
recommended oil as needed. Do not
overfill.
4. Reinstall the fill plug, making sure it
is seated properly.
68
3
1
2
MAINTENANCE
Lubrication
Chaincase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Remove the drain plug (4) and drain
the oil into a drain pan. Allow the oil
to drain completely.
3. Clean off all metal shavings from the
plug.
4. Install a new sealing washer on the
drain plug.
4
Tip: The sealing surfaces on the drain plug and the oil tank should be clean and
free of burrs, nicks or scratches.
5.
6.
7.
8.
Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
Remove the fill plug. Clean off all metal shavings from the plug.
Add 9 oz. (265 ml) of the recommended oil. Do not overfill.
Reinstall the fill plug, making sure it is seated properly.
69
MAINTENANCE
Spark Plugs
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. Change the spark plugs every 2000-2500 miles (32004000 km).
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 the specifications section beginning on page 98.
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.
• Use only resistor-type spark plugs.
• 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.
70
MAINTENANCE
Spark Plugs
Spark Plug Condition
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.
2.
3.
4.
5.
Remove the spark plug cap.
Rotate the spark plug counter-clockwise to remove it.
Reverse the procedure for spark plug installation.
Torque to 18-22 ft. lbs. (24-30 Nm).
Reinstall the spark plug cap.
71
MAINTENANCE
Intake Filters
The intake foam filters limit snow
ingestion into the intake system.
When operating in loose powder
snow, check the foam filters period- X
ically 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.
Oil Lines
Inspect oil line condition every 1000 miles (1600 km).
Oil Filter
The oil filter is located at the side of
the oil tank. Have your dealer change
the oil filter and bleed the system
annually or every 1000 miles (1600
km).
Tip: The direction of the arrows indicates
the direction of flow through the filter.
Fuel Pump
All fuel pump service must be performed by an authorized POLARIS
dealer. Do not attempt to service the fuel pump.
72
MAINTENANCE
Fuel Filter/Fuel Lines
See your POLARIS dealer for replacement of the under-tank fuel filter
every 1000 miles (or annually).
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.
Cooling System
Inspect the fan intake and outlet edge seal at the input and output for
cracks, loosening of duct and blockage or obstructions. Make any necessary repairs promptly.
Exhaust System
Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). Always allow the engine and exhaust system to cool
completely before inspecting.
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.
1. Open the hood and inspect the muffler and pipes for cracks or damage.
2. Check for weak or missing retaining springs or damper/support
grommets.
3. Check for loose clamps on the pipe covers.
73
MAINTENANCE
Carburetor
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
74
MAINTENANCE
Carburetor Water/Sediment Trap
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 about every 1000 miles
(1600 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 fuel
warnings on page 51.
Cleaning Procedure
1. Turn the fuel valve off.
2. Place a container or shop
1
towels below the plug to
catch drained fuel.
2
3. Slide the clamp (1) away
from the drain plug (2) and
remove the drain plug from
the sediment tube.
4. Wipe residue from the plug and reinstall it. Reposition and tighten
the clamp.
5. Repeat the draining procedure for any remaining traps.
75
MAINTENANCE
Drive Chain Tension
Check drive chain tension weekly and
before each long trip. To obtain correct
chain tension:
1. Rotate the driven clutch counterclockwise to move all chain slack to
the tensioner side. Lock the brake
lever lock, or have an assistant hold
the brake lever firmly.
2. Loosen the adjuster bolt jam nut (1).
3. Finger tighten the adjuster bolt (2)
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.
76
2
1
MAINTENANCE
Brakes
Hydraulic Brake Inspection
Inspect brake lever travel before each use of the snowmobile. See page
42.
Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16” or 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” or 1.5 mm
Brake Components
1. Brake Caliper
2. Brake Disc
3. Brake Pad Material
(Replace when thickness is
less than 1/16” or 1.5 mm).
3
1
2
Excessive Lever Travel
Hydraulic brakes are selfadjusting, but if excessive
brake pad clearance develops,
bring the machine to an authorized POLARIS dealer for
inspection and adjustment.
77
MAINTENANCE
Brakes
Brake Fluid
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or serious injury.
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.
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.
Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid. See page 102 for the part numbers of POLARIS
products.
NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe
up spills immediately.
78
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 1/4-5/16 inch (.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 78.
8. Reinstall the gasket and cover.
79
MAINTENANCE
Lights
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 Removal
1. Remove the plenum covering
from the headlight assembly.
2. Lift the rubber boot to expose
the bulb.
2
3. Push down on the spring (1) to
release it from the housing.
4. With the wire harness (2)
attached to the bulb (3), with1
draw the bulb from the housing.
5. Grasp the bulb by its metal base
and carefully separate the bulb from the harness.
3
Headlight Bulb Installation
1. Hold the bulb by its metal base and install it into the wire harness.
Tip: Recommended replacement bulbs include H4, HB2 and 9003 bulbs.
2. Insert the bulb into the housing.
3. Connect the spring to the housing.
4. Carefully flip the spring back into the housing, placing it around the
wire harness.
5. Reinstall the plenum covering on the headlight assembly.
6. Verify headlight aim.
80
MAINTENANCE
Lights
Taillight/Brakelight Replacement
1. Remove the screws securing the taillight lens. Remove the lens.
2. Push the bulb inward and turn it counter-clockwise to remove it.
3. Install a new bulb. Push the bulb inward and turn it clockwise to
secure it.
4. Reinstall the taillight lens.
81
MAINTENANCE
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.
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. See your dealer for service and adjustments. A special tool is
required to check for proper alignment.
82
MAINTENANCE
Clutch System
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 Drive Belt Troubleshooting on page
107.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.
Drive Belt Removal
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.
1. Stop the engine after operating in a forward motion.
2. Turn the ignition key off. Wait for the engine to come to a complete
stop.
3. Lock the parking brake.
4. Open the hood.
5. Remove the left side panel.
6. Locate the L-wrench in the tool kit. Install the wrench into the open
threaded hole in the outer sheave of the clutch.
7. Turn the wrench clockwise until the sheaves open far enough to
remove the belt.
83
MAINTENANCE
Clutch System
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back the
slack. The belt cord line
should be flush with, or
slightly above, the outer circumference of the driven
clutch sheaves. The belt will
seat itself in the driven clutch
during the break-in period.
Adjust the belt ride-out after
the break-in period by readjusting belt deflection.
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. Rotate the L-wrench counter-clockwise to tighten the sheaves while
working the belt to the outer edge of the sheaves.
3. Remove the L-wrench and store it in the tool kit.
4. Reinstall the side panel.
5. Close and secure the hood.
6. Break in the new belt. See page 49.
Drive Belt
Belt width and length must match the center distance of the clutches and
sheave width of the drive clutch. POLARIS recommends the use of
O.E.M. belts. Other belts may match the dimensions, but can drastically
change the shift pattern, resulting in poor performance.
Tip: A worn belt will continue to function, but will not deliver maximum performance. Always carry a spare belt in case of an emergency.
84
MAINTENANCE
Clutch System
Drive Belt Deflection
1
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 inch
(3.2 cm).
2
Drive Belt Adjustment
1. Install the L-wrench into the open threaded hole in the outer sheave
of the clutch (see page 83). Turn the wrench clockwise slightly to
remove pressure from the sheaves.
2. Loosen the 7/16-inch jam nut.
3. Using a 1/8-inch Allen wrench, turn the set screw inward (clockwise) to increase the distance between the sheaves or outward
(counter-clockwise) to decrease the distance.
4. Tighten the jam nut. Store the L-wrench in the tool kit.
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.
.010-.030 inch
(.25-.75 mm)
85
MAINTENANCE
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 (X). Bend the track
to check for breakage.
4. Replace the track if any rod
damage is found.
86
X
MAINTENANCE
Track Maintenance
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.
87
MAINTENANCE
Track Maintenance
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.
TRACK TENSION DATA CHART
Measurement
Location
Slack
Measurement
10 lbs. (4.54 kg)
16 in. (40 cm)
ahead of rear
idler shaft
7/8-1 1/8 in.
(2.2-2.9 cm)
10 lbs. (4.54 kg)
16" (40 cm)
ahead of rear
idler shaft
7/8-1 1/8 in.
(2.2-2.9 cm)
Suspension
Weight
IQ (121)
IQ Comfort (136)
Tip: Tension adjustments should be made only after the track is warmed up and
limber.
1. Turn the engine off.
2. Lift the rear of the 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. Measure at the point where the weight is hanging.
88
MAINTENANCE
Track Maintenance
Track Tension
4. Check for specified slack between the wear surface of the track clip
and the plastic slider. Refer to the Track Tension Data Chart on page
88.
If the track needs adjustment:
5. Loosen the rear idler shaft bolt.
6. Loosen the locknuts.
Slack Measurement
Adjusting Screw
Lock Nut
Shaft
Bolt
Track
10 lbs.
(4.54 kg)
16 in. (40 cm)
7. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track.
8. Repeat the measurement on the other side of the track.
Tip: Check more frequently when the machine is new.
9. Start the machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).
10. Check track alignment (see page 90) and adjust as necessary.
11. Tighten the locknuts.
12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).
89
MAINTENANCE
Track Maintenance
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 (X) 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 comX
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.
90
MAINTENANCE
Steering System
Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.
X
X
X
X
X
91
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.
1. Place the handlebars in a straight-ahead position.
2. With only vehicle weight compressing the suspension, measure 10
inches (25.4 cm) forward from the center of the ski mounting bolt.
See illustration. At this point, measure between the skis. This is
measurement X.
3. Perform the same measurement rearward from the center of the ski
mounting bolt. This is measurement Y.
4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than
the Y measurement. If the skis are misaligned, see your dealer for
alignment correction as camber adjustment may also be affected.
X
10 in.
(25.4 cm)
10 in.
(25.4 cm)
Y
92
MAINTENANCE
Steering System
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.
Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original diameter.
Tip: 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 6 inches (15.2
cm) from the ground.
2. Remove the attaching nuts
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.
93
MAINTENANCE
Steering System
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.
94
Minimum
Thickness
Replace when
worn to top of
groove
MAINTENANCE
Daily Storage
At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be
suspended approximately 4 inches (10 cm) off the ground.
Remove the key and cover the machine.
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
Extended Storage
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components. See page 102 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 all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 63.
95
MAINTENANCE
Extended Storage
Bearings
Grease the jackshaft and drive shaft clutch side bearings with POLARIS
Premium All-Season Grease or a similar high quality grease to prevent
corrosion.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Do not lubricate
clutch components, except the driven clutch shaft bushing as outlined in
the 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. Do not allow the snowmobile to run out of fuel.
If stabilizer is not used, drain the carburetors by removing the water trap
drain plugs. See page 75.
Tip: Jet restriction caused by improper storage can cause lean conditions and
very poor slow speed driving quality.
96
MAINTENANCE
Extended Storage
Electrical Connections
Replace worn or frayed electrical wire and connectors. Be sure wiring
harness is properly secured away from sharp edges, steering linkage,
moving parts, and hot exhaust parts.
Track and Suspension
Moderate track tension should be maintained during summer storage.
The 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 52.
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.
97
SPECIFICATIONS
550 IQ SHIFT
Capacities and Dimensions
Body Style
Rider Capacity
Coolant Capacity
Fuel Capacity
Oil Capacity
Gearcase Oil Capacity
Length
Width
Height
Brake Type
Drive Clutch Center Distance
Drive Belt P/N
Clutch Type
Reverse Transmission
IQ
1
N/A
11.5 gal. (43.5 l)
3 qts. (2.8 l)
8.96 oz. (265 ml)
115 in. (292 cm)
47.25 in. (120 cm)
44.5 in. (113 cm)
Hayes Phantom DOT 4
11 in. (28 cm)
3211121
P-85
Electronic Reverse
Engine and Cooling
Engine
Displacement
Cylinders
Bore x Stroke (mm)
Alternator Output
Carburetor/Throttle Body
Carburetor Model
Idle RPM
Cooling
Ignition Type
Ignition Timing
Spark Plug / Gap
EC55PM0124
544 cc
2
73x65
280 watt
2 Mikuni
VM34
1700 +/- 200
Fan Air
Kokusan 16 Bit ER
15° BTDC @ 1600 RPM, 17° BTDC @ 6500 RPM
NGK BR9ES / .028 in. (0.70 mm)
Electric Fuel Gauge
Electric Start
Low Oil Light
Parking Brake
Speedometer
Tachometer
N/A
Accessory (Standard on ES models)
Standard
Standard
Standard
Accessory
Features
Carburetor Settings
Main Jet
Pilot Jet
Jet Needle
Needle Jet
Cutaway
Throttle Gap Under CA
Fuel Screw (from fully seated)
Air Screw (from fully seated)
Pilot Air Jet
98
250
45
6BGY48
Q-0 (480)
3
6.98 mm / .275 in.
N/A
1.5 Turns
2.5
SPECIFICATIONS
550 IQ SHIFT
Carburetor Jetting
*Shaded cells indicate factory settings.
AMBIENT TEMPERATURE
°F:
ALTITUDE
Meters
(Feet)
°C:
Main Jet
0-600
(0-2000)
Pilot Jet
Clip Position
Main Jet
600-1200
(2000-4000)
Pilot Jet
Clip Position
Main Jet
1200-1800
(4000-6000)
Pilot Jet
Clip Position
Main Jet
1800-2400
(6000-8000)
2400-3000
(800010000)
3000-3700
(1000012000)
Pilot Jet
Clip Position
Main Jet
Pilot Jet
Clip Position
Main Jet
Pilot Jet
Clip Position
Below -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65
-25
Below -34 to -23 -26 to -15 -18 to -7
-9 to +2
-1 to +10
+7 to +18
-35
270
260
250
240
230
220
210
45
45
45
45
45
45
45
#4
#4
#4
#4
#4
#3
#2
260
250
240
230
220
210
210
#4
#4
#4
#3
#3
#2
#2
45
45
45
45
45
45
45
240
230
220
210
200
200
190
45
45
45
45
45
45
45
#4
#4
#3
#3
#2
#2
#2
220
210
200
190
180
180
170
45
45
45
45
45
45
45
#4
#4
#3
#3
#2
#2
#1
210
200
190
180
175
170
160
45
45
45
45
45
45
45
#4
#3
#3
#2
#2
#2
#1
200
190
180
170
170
160
150
45
45
45
45
45
45
45
#4
#3
#2
#2
#1
#1
#1
Above
+60
Above
+16
200
45
#2
200
#1
45
180
45
#1
170
45
#1
160
45
#1
150
45
#1
The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR
1051.115(d)(3) and is an acceptable alternative to the use of tamper-resistant features.
550 IQ SHIFT
Clutching Chart
ALTITUDE
Meters (Feet)
Drive Clutch
Shift Weight
Drive Clutch
Spring
Driven Clutch
Spring
Driven Helix
Chaincase
Gearing/
Pitch
*Shaded cells indicate factory settings.
0-600
(0-2000)
10-64
(1321585)
120/310 Black
(7043681)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
20:41
76P
600-1200
(2000-4000)
10-62
(1321586)
120/310 Black
(7043681)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
20:41
76P
1200-1800
(4000-6000)
10-62
(1321586)
120/310 Black
(7043681)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
20:41
76P
1800-2400
(6000-8000)
10-60
(1321587)
120/310 Black
(7043681)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
19:41
76P
2400-3000
(8000-10000)
10-58
(1321588)
120/310 Black
(7043681)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
19:41
76P
3000-3600
(10000-12000)
10-56
(1321684)
Dark Blue
(7041526)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
19:41
76P
99
SPECIFICATIONS
550 IQ 136 / 550 IQ LXT
Capacities and Dimensions
Body Style
Rider Capacity
Coolant Capacity
Fuel Capacity
Oil Capacity
Gearcase Oil Capacity
Length
Width
Height
Brake Type
Drive Clutch Center Distance
Drive Belt P/N
Clutch Type
Reverse Transmission
IQ
Shift 136/ES: 1 Rider
IQ LXT: 2 Riders
N/A
11.5 gal. (43.5 l)
3 qts. (2.8 l)
8.96 oz. (265 ml)
125 in. (318 cm)
47.25 in. (120 cm)
44.5 in. (113 cm) (low windshield)
48 in. (122 cm) (high windshield)
Hayes Phantom DOT 4
11 in. (28 cm)
3211121
P-85
Electronic Reverse
Engine and Cooling
Engine
Displacement
Cylinders
Bore x Stroke (mm)
Alternator Output
Carburetor/Throttle Body
Carburetor Model
Idle RPM
Cooling
Ignition Type
Ignition Timing
Spark Plug / Gap
EC55PM0124
544 cc
2
73x65
280 watt
2 Mikuni
VM34
1700 +/- 200
Fan Air
Kokusan 16 Bit ER
15° BTDC @ 1600 RPM, 17° BTDC @ 6500 RPM
NGK BR9ES / .028 in. (0.70 mm)
Electric Fuel Gauge
Electric Start
Low Oil Light
Parking Brake
Speedometer
Tachometer
N/A
Accessory (Standard on LXT and ES models)
Standard
Standard
Standard
Accessory
Features
Carburetor Settings
Main Jet
Pilot Jet
Jet Needle
Needle Jet
Cutaway
Throttle Gap Under CA
Fuel Screw (from fully seated)
Air Screw (from fully seated)
Pilot Air Jet
100
250
45
6BGY48
Q-0 (480)
3
6.98 mm / .275 in.
N/A
1.5 Turns
2.5
SPECIFICATIONS
550 IQ 136 / 550 IQ LXT
Carburetor Jetting
*Shaded cells indicate factory settings.
AMBIENT TEMPERATURE
°F:
ALTITUDE
Meters
(Feet)
°C:
Main Jet
0-600
(0-2000)
Pilot Jet
Clip Position
Main Jet
600-1200
(2000-4000)
Pilot Jet
Clip Position
Main Jet
1200-1800
(4000-6000)
Pilot Jet
Clip Position
Main Jet
1800-2400
(6000-8000)
2400-3000
(800010000)
3000-3700
(1000012000)
Pilot Jet
Clip Position
Main Jet
Pilot Jet
Clip Position
Main Jet
Pilot Jet
Clip Position
Below -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65
-25
Below -34 to -23 -26 to -15 -18 to -7
-9 to +2
-1 to +10
+7 to +18
-35
270
260
250
240
230
220
210
45
45
45
45
45
45
45
#4
#4
#4
#4
#4
#3
#2
260
250
240
230
220
210
210
#4
#4
#4
#3
#3
#2
#2
45
45
45
45
45
45
45
240
230
220
210
200
200
190
45
45
45
45
45
45
45
#4
#4
#3
#3
#2
#2
#2
220
210
200
190
180
180
170
45
45
45
45
45
45
45
#4
#4
#3
#3
#2
#2
#1
210
200
190
180
175
170
160
45
45
45
45
45
45
45
#4
#3
#3
#2
#2
#2
#1
200
190
180
170
170
160
150
45
45
45
45
45
45
45
#4
#3
#2
#2
#1
#1
#1
Above
+60
Above
+16
200
45
#2
200
#1
45
180
45
#1
170
45
#1
160
45
#1
150
45
#1
The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR
1051.115(d)(3) and is an acceptable alternative to the use of tamper-resistant features.
550 IQ 136 / 550 IQ LXT
Clutching Chart
ALTITUDE
Meters (Feet)
Drive Clutch
Shift Weight
Drive Clutch
Spring
Driven Clutch
Spring
Driven Helix
Chaincase
Gearing/
Pitch
*Shaded cells indicate factory settings.
0-600
(0-2000)
11-66
(1322597)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
600-1200
(2000-4000)
11-64 CS
(1322604)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
1200-1800
(4000-6000)
11-62
(1322862)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
1800-2400
(6000-8000)
11-60
(1322863)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
2400-3000
(8000-10000)
11-58
(1322864)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
3000-3600
(10000-12000)
11-56
(1322865)
90-280 Black
(7043677)
130/180 P2 Tab
(7043515)
42S P2N N/A
(5137155)
18:42
76P
101
POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
2870791
Fogging Oil (12 oz./355 ml Aerosol)
2875035
Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l)
2875036
Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l)
2875038
Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l)
2877882
VES Gold Plus 2-Cycle Oil (qt./.95 l)
2877883
VES Gold Plus 2-Cycle Oil (gal./3.8 l)
2877884
VES Gold Plus 2-Cycle Oil (2.5 gal./9.5 l)
Chaincase Lubricants
2873105
Synthetic Chaincase Lubricant (qt./.95 l)
2872951
Synthetic Chaincase Lubricant (12 oz./355 ml)
2871312
Grease Gun Kit, Premium All Season (3 oz./89 ml)
2871322
Premium All Season Grease (3 oz./89 ml cartridge)
2871423
Premium All Season Grease (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel™)
Grease/Specialized Lubricants
Additives/Miscellaneous
2871326
Carbon Clean Plus
2870652
Fuel Stabilizer
2872189
DOT 4 Brake Fluid
2872893
Engine Degreaser
2870505
Isopropyl
2872889
Brake and Clutch Cleaner
2872890
Carb and Throttle Body Cleaner
102
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
Engine stutters in
reverse
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.
Misfire mode has
activated to prevent
engine overheat
• Shift to forward or restart the engine
to clear the misfire mode.
103
TROUBLESHOOTING
Engine 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.
Poor low RPM performance
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.
Engine doesn't turn
104
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.
Incorrect clutching
• SEE YOUR DEALER.
Carburetor and fuel
pump
• SEE YOUR DEALER.
Engine lacks power
Engine continually
backfires
Make sure the fuel valve is on.
Use the choke.
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.
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.
105
TROUBLESHOOTING
Rear Suspension Troubleshooting
Problem
Solution
Rear suspension bottoms too easily
• Adjust torsion spring preload to achieve proper static sag
(see page 32).
• Change torsion spring to stiffer optional spring (see your
dealer).
• Revalve rear track shock (see your dealer).
• Rotate RRSS to higher position (see page 36).
Rides too stiff in rear
• Check for binding suspension shafts and grease all pivot
points.
• Adjust torsion spring preload to achieve proper static sag
(see page 32).
• Change torsion spring to softer optional spring (see your
dealer).
• Check track tension (see page 88).
• Rotate RRSS to lower position (see page 36).
Machine darts from
side to side
• Check ski alignment (see page 92).
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Ensure skags are straight on skis.
• Set static sag (see page 32).
• Check rail slide/replace if worn (see page 94).
• Install Accu-Trak dual skags (see your dealer).
Front end pushes
• Check for worn skags.
• Check for binding front suspension shafts and steering
components, grease all pivot points (elevate front of
machine).
• Set static sag (see page 32).
• Install single skag (see your dealer).
• Increase IFS preload (if equipped) (see page 28).
• Rotate RRSS to higher position (see page 36).
Steering is heavy
•
•
•
•
106
Make sure spindles and all steering components turn freely.
Check ski alignment (see page 92).
Check skags and skis for damage.
Set static sag (see page 32).
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
107
WARRANTY
Service and Warranty Information
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
108
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.
109
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.
110
WARRANTY
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. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT
FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY
FAILED OF ITS ESSENTIAL PURPOSE. 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.
111
WARRANTY
Warranty Coverage and Exclusions
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.
Promotional Warranties
Promotional warranties are sometimes offered by POLARIS. These warranties can be,
but are not limited to:
• Two-year extended engine coverage
• Two-year powertrain coverage
• Extended service contract
If you selected any type of extended warranty coverage as part of a POLARIS retail program, please contact any authorized POLARIS dealer for additional information.
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.
112
WARRANTY
Warranty Coverage and Exclusions
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested
by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehicle 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
113
WARRANTY
Warranty Coverage and Exclusions
Conditions and Exclusions
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.
114
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 Bulletins.
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.
115
WARRANTY
Exported Vehicles
How to Get Service
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. You should warranty register your
vehicle at a local POLARIS dealer in your new country immediately after you move to
continue your warranty coverage and to ensure that you receive safety information and
notices regarding your vehicle.
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. You
must nonetheless warranty register your vehicle under your name and address with a
local POLARIS dealer in your country to ensure that you receive safety information and
notices regarding your vehicle.
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, other than safety bulletins. (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 108).
116
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
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
117
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. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
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.
118
MAINTENANCE LOG
Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an
accurate log of maintenance and services performed on the snowmobile.
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
150 mi.
(240 km)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
119
MAINTENANCE LOG
DATE
120
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
121
INDEX
A
C
Accessories . . . . . . . . . . . . . . . . . . . 39
Adjustable Headlights . . . . . . . . . . . 27
Air Pollution . . . . . . . . . . . . . . . . . . . 5
Altitude Setting . . . . . . . . . . . . . . . . 59
Avalanches. . . . . . . . . . . . . . . . . . . . 13
Clutch System . . . . . . . . . . . . . . . 82-85
Clutching
550 IQ SHIFT . . . . . . . . . . . . . . 99
550 IQ 136/LXT . . . . . . . . . . . 101
Cold Weather Drive-Away . . . . . . . . 17
Controls and Linkage . . . . . . . . . . . . 95
Coolant . . . . . . . . . . . . . . . . . . . . . . . 73
Cooling System . . . . . . . . . . . . . . . . . 73
Customer Service . . . . . . . . . . . . . . 108
B
Bearings . . . . . . . . . . . . . . . . . . . . . . 96
Before Starting the Engine. . . . . . . . 41
Bleeding the Brake System . . . . . . . 79
Brake Components. . . . . . . . . . . . . . 77
Brake Fluid . . . . . . . . . . . . . . . . . . . 78
Brake Inspection . . . . . . . . . . . . . . . 77
Brake Lever Travel . . . . . . . . . . 42, 77
Brake System Bleeding . . . . . . . . . . 79
Brakelight Replacement. . . . . . . . . . 81
Brakes . . . . . . . . . . . . . . . . . . 42, 77-79
Break-In Period . . . . . . . . . . . . . . 48-49
C
Carbide Skags . . . . . . . . . . . . . . . . . 37
Carburetion . . . . . . . . . . . . . . . . . 54-55
Carburetor . . . . . . . . . . . . . . . . . . . . 74
Carburetor Adjustments. . . . . . . . . . 74
Carburetor Jetting
550 IQ SHIFT . . . . . . . . . . . . . 99
550 IQ 136/LXT . . . . . . . . . . 101
Carburetor Protection. . . . . . . . . . . . 96
Carburetor Water/Sediment Trap . . 75
Cargo Bag . . . . . . . . . . . . . . . . . . . . 27
Cargo Overload . . . . . . . . . . . . . . . . 10
Chaincase Oil. . . . . . . . . . . . . . . . 68-69
Choke. . . . . . . . . . . . . . . . . . . . . . . . 67
Choke Cable. . . . . . . . . . . . . . . . . . . 67
Choke Operation . . . . . . . . . . . . . . . 47
Cleaning and Preservation . . . . . . . . 95
Clutch Alignment Offset . . . . . . . . . 82
Clutch and Drive System . . . . . . . . . 96
Clutch Cover Warning. . . . . . . . . . . 21
Clutch Safety . . . . . . . . . . . . . . . . . . 17
122
D
Disabled Operators . . . . . . . . . . . . . . 10
Drive Belt . . . . . . . . . . . . . . . . . . 17, 84
Drive Belt Adjustment . . . . . . . . . . . 85
Drive Belt Break-In. . . . . . . . . . . . . . 49
Drive Belt Condition . . . . . . . . . . . . . 83
Drive Belt Deflection . . . . . . . . . . . . 85
Drive Belt Installation . . . . . . . . . . . . 84
Drive Belt Removal. . . . . . . . . . . . . . 83
Drive Belt Troubleshooting. . . . . . . 107
Drive Chain Tension . . . . . . . . . . . . . 76
Driver Awareness . . . . . . . . . . . . . . . 12
Driveshaft Bearing . . . . . . . . . . . . . . 67
Driving Downhill . . . . . . . . . . . . . . . 15
Driving in Hilly Terrain . . . . . . . . . . 16
Driving on Slippery Surfaces . . . . . . 14
Driving Responsibly . . . . . . . . . . . . . 19
E
Electrical Connections . . . . . . . . . . . 97
Emissions Limited Warranty. . 117-118
Engine Break-In . . . . . . . . . . . . . . . . 48
Engine Protection . . . . . . . . . . . . . . . 96
Engine Safety . . . . . . . . . . . . . . . . . . . 8
Engine Stop Switch . . . . . . . . . . . . . . 56
Environment . . . . . . . . . . . . . . . . . . . . 5
Exhaust System . . . . . . . . . . . . . . . . . 73
INDEX
F
M
Front Rear Scissor Stop . . . . . . . . . . 34
Front Suspension Adjustments . . 28-29
Front To Rear Coupling . . . . . . . . . . 34
FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel . . . . . . . . . . . . . . . . . . . . . . . 51-52
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 73
Fuel Pump . . . . . . . . . . . . . . . . . . . . . 72
Fuel System Deicers . . . . . . . . . . . . . 52
Fuel Valve. . . . . . . . . . . . . . . . . . . . . 52
Maintenance . . . . . . . . . . . . . . . . . . . 17
Maintenance Interval Table . . . . 63-65
Maintenance Log . . . . . . . . . . 119-121
Maintenance Program. . . . . . . . . . . . 62
Maneuverability . . . . . . . . . . . . . . . . 17
G
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 72
Oil Injection System. . . . . . . . . . . . . 49
Oil Level. . . . . . . . . . . . . . . . . . . . . . 53
Oil Lines . . . . . . . . . . . . . . . . . . . . . . 72
Oil Recommendations . . . . . . . . . . . 49
Operation Warning . . . . . . . . . . . 23-24
Operator Safety. . . . . . . . . . . . . . . 6-20
Grab Handle Adjustment . . . . . . . . . 27
H
Handlebar Adjustments. . . . . . . . . . .
Headlight Adjustment . . . . . . . . . . . .
Headlight Bulb Installation . . . . . . . .
Headlight Bulb Removal . . . . . . . . .
Hood Latches . . . . . . . . . . . . . . . . . .
38
27
80
80
45
I
Ice and Snow Build-up . . . . . . . . . . .
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . .
IFS Adjustment Options . . . . . . . . . .
IFS Components . . . . . . . . . . . . . . . .
Inadequate Snow Conditions . . . . . .
Intake Filters . . . . . . . . . . . . . . . . . . .
Intake Silencer . . . . . . . . . . . . . . . . .
14
28
28
28
18
72
17
J
Jetting Guidelines . . . . . . . . . . . . . . . 55
L
Lights . . . . . . . . . . . . . . . . . . . . . 80-81
Limiter Strap Position . . . . . . . . . . . . 33
Low Oil Indicator Light . . . . . . . . . . 53
Lubrication . . . . . . . . . . . . . . . . . 66-69
N
No Passenger Warning . . . . . . . . . . . 22
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . 5
O
P
Park Brake Lever Lock. . . . . . . . . . . 43
Passenger Warning . . . . . . . . . . . . . . 22
Polaris Products . . . . . . . . . . . . . . . 102
Preload, IFS Shock Spring . . . . . . . . 29
Pre-Ride Checklist . . . . . . . . . . . . . . 40
Pre-Ride Suspension Inspection. . . . 45
R
Rail Slide Wear . . . . . . . . . . . . . . . . 94
Rear Rear Scissor Stop . . . . . . . . . . . 35
Rear Suspension Adjustments . . 30-36
Rear To Front Coupling . . . . . . . . . . 35
Recoil Rope . . . . . . . . . . . . . . . . . . . 45
Recommended Maintenance . . . . . . . 7
Registration, Warranty . . . . . . . . . . 110
Reverse . . . . . . . . . . . . . . . . . . . . 58-59
Reverse Warning . . . . . . . . . . . . . . . 23
123
INDEX
R
T
Rider Capacity . . . . . . . . . . . . . . . . . 11
Riding Apparel. . . . . . . . . . . . . . . . . . 9
Riding Position . . . . . . . . . . . . . . . . . 8
RRSS . . . . . . . . . . . . . . . . . . . . . . . . 35
Taillight/Brakelight Replacement . . . 81
Throttle Cable . . . . . . . . . . . . . . . . . . 67
Throttle Lever . . . . . . . . . . . . . . . 41, 57
Throttle Safety Switch. . . . . . . . . 41, 56
Torque Stop. . . . . . . . . . . . . . . . . . . . 85
Torsion Spring Preload, IQ . . . . . . . . 33
Towing . . . . . . . . . . . . . . . . . . . . . . . 60
Track . . . . . . . . . . . . . . . . . . . . . . . . . 44
Track Alignment . . . . . . . . . . . . . . . . 90
Track Care for Storage . . . . . . . . . . . 97
Track Inspection . . . . . . . . . . . . . . . . 86
Track Lubrication . . . . . . . . . . . . . . . 87
Track Maintenance . . . . . . . . . . . 86-90
Track Safety . . . . . . . . . . . . . . . . . . . . 8
Track Tension . . . . . . . . . . . . . . . 31, 88
Track Warm-Up . . . . . . . . . . . . . . . . 50
Track Warning . . . . . . . . . . . . . . . . . 22
Traction Products . . . . . . . . . . . . . . . 37
Transporting the Snowmobile . . . . . . 97
Troubleshooting, Drive Belt . . . . . . 107
Troubleshooting, Engine . . . . . 103-105
Troubleshooting, Rear Suspension . 106
Tune-Up . . . . . . . . . . . . . . . . . . . . . . 95
S
Safety Decals . . . . . . . . . . . . . . . . 21-24
Safety Symbols . . . . . . . . . . . . . . . . . 6
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sediment Trap . . . . . . . . . . . . . . . . . 75
Signal Words . . . . . . . . . . . . . . . . . . . 6
Ski Alignment . . . . . . . . . . . . . . . . . 92
Ski Pressure . . . . . . . . . . . . . . . . . . . 33
Ski Skags . . . . . . . . . . . . . . . . . . . . . 93
Slide Rail and Track Cooling . . . . . 50
Snow Conditions . . . . . . . . . . . . . . . 18
Spark Plug . . . . . . . . . . . . . . . . . . . . 71
Spark Plug Condition. . . . . . . . . . . . 71
Spark Plugs . . . . . . . . . . . . . . . . . 70-71
Specifications. . . . . . . . . . . . . . . . . . 98
Speed . . . . . . . . . . . . . . . . . . . . . . . . 11
Spring Preload . . . . . . . . . . . . . . . . . 32
Spring Preload, IFS Shock. . . . . . . . 29
Spring Preload, Rear, IQ . . . . . . . . . 32
Starting the Engine . . . . . . . . . . . . . 47
Steering Inspection/Adjustment. . . . 91
Steering System . . . . . . . . . . . 44, 91-94
Stopping, Emergency. . . . . . . . . . . . 48
Storage, Daily . . . . . . . . . . . . . . . . . 95
Storage, Extended . . . . . . . . . . . . 95-97
Survival Preparation . . . . . . . . . . . . 10
Suspension Coupling, IQ . . . . . . . 34-35
Suspension Inspection, Pre-Ride . . . 45
Suspension Performance Tips . . . . . 31
Suspension, Front, Lubrication . . . . 66
Suspension, Rear, Lubrication. . . . . 66
124
V
Vehicle Identification Numbers . . . . . 4
W
Wear Strips . . . . . . . . . . . . . . . . . . . .
Weight Transfer . . . . . . . . . . . . . . . .
Windchill. . . . . . . . . . . . . . . . . . . . . .
Windchill/Temperature Charts . . . . .
37
36
20
20