Polaris 600 IQ LXT Owner Manual

Polaris 600 IQ LXT Owner Manual

PMS 419 600 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).

PMS 419

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. 9923381 Rev 01 Printed in USA

*9923381 *

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit ing 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 pro duced.

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 ser vice needs during, and after, the warranty period. We also take great pride in our complete line of apparel, parts and acces sories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

1

The following are registered trademarks of POLARIS Industries Inc.: POLARIS ® THE WAY OUT ® IQ ® RIDER SELECT ® PERC ® Copyright 2011 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 discrep ancies may result between the actual vehicle and the information presented in this publi cation. 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.

2012 600 IQ LXT Owner’s Manual P/N 9923381 2

TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

This section describes safe vehicle operation and identifies warning decals and their locations.

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

This section identifies the locations of your snowmobile’s controls and features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 50

This section explains how to tailor the suspension and other features for an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 64

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

This section explains proper engine break-in, operation of features and general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

This section defines your role, and your dealer’s role, in your snowmo bile’s regular maintenance.

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 118 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 133 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

3

4

INTRODUCTION Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient ref erence. It should remain with the snowmobile when the snowmobile is sold.

Some of the illustrations and photos used in this manual are general rep resentations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding clubs.

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.

5

6

INTRODUCTION Preservation of the Environment

POLARIS is committed to supporting an environmental education cam paign. We encourage state and provincial governments across the snow belt 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 pro tect 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 stan dards. 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 manufac turing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Vehicle Identification Numbers INTRODUCTION

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: ____________________________________________________________ (lower right side of the tunnel) Engine Serial Number (on recoil housing): _____________________________________ Key Number: ___________________________________________________________ 7

8

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 sym bols are used. Become familiar with their meanings before reading the manual.

The

safety alert symbol

, on your vehicle or in this manual, indicates the potential for serious injury.

WARNING

A WARNING indicates a potential hazard that may result in serious injury or death.

CAUTION

A CAUTION indicates a potential hazard that may result in minor injury.

NOTICE

A NOTICE indicates a situation that may result in damage to the vehicle.

SAFETY Operator Safety

Follow the recommended maintenance program outlined beginning on page 84 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 aerody namically 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 haz ard and lead to bodily injury.

The warranty on your entire machine is terminated

power of the snowmobile.

if any equipment has been added, or any modifications have been made, to increase the speed or 9

SAFETY Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.

WARNING!

Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

Never

attempt adjustments with the engine running. Turn off the igni tion, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.

WARNING!

Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.

10

SAFETY Operator Safety

Riding Position

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

WARNING!

serious injury or death. Always ride in a position that allows for control of your vehicle.

Improper riding position may reduce control and could result in

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 condi tions you may encounter. Such equipment may include, but is not lim ited 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 cel lular telephone.

Always carry the owner’s manual on your snowmobile. For added pro tection, purchase and carry the following items on your snowmobile as well: • Spare Drive Belt • Extra Set of Spark Plugs • Tow Rope • Extra Oil • Fuel Deicer • Winter Survival Kit • Trail Map • First Aid Kit • Tool Kit 11

SAFETY Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab lished 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 distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Eye Protection E 4 051039 0006.31

Do not depend on eyeglasses or sunglasses for eye protection. When ever 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.

Clothing

Be prepared, be warm and be com fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 23.

WARNING!

Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.

12

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.

Driving 2-Up -

Some POLARIS snowmobiles are designed for up to two riders. A decal on the

hood

of these models indicates that the vehi cle 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!

for stopping.

Control becomes more difficult with two people on board. More space is required to make turns, and longer distances are necessary 13

SAFETY Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills.

WARNING!

Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle.

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier.

14

SAFETY Operator Safety

Excessive Speed

WARNING!

High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather.

Always observe all state and local laws governing snowmobile opera tion 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 snowmobile to a stop in the distance illu minated by the headlight. 15

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.

out the sound of approaching vehicles. Look ahead, behind, and to both sides or highways. Steep embankments may a way out.

The noise of your snowmobile will drown before turning or crossing railroad tracks also hide your view. Always leave yourself

R R

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is suffi ciently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities and residents to confirm ice condi tions and thickness over your entire route. Snowmobile operators assume all risk associated with ice conditions on frozen bodies of water.

16

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 ava lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi tions, contact local law enforcement in your area, or visit the American and Canadian online avalanche centers at www.avalanche.org.

17

SAFETY Operator Safety

Ice and Snow Build-up

WARNING!

Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

If your snowmobile is equipped with RIDER SELECT, perform this check in both the full up and full down steering positions.

Driving Downhill

When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine’s compression to help slow the snowmobile and keep it from rolling freely downhill.

WARNING!

When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

18

SAFETY Operator Safety

Driving on Slippery Surfaces

WARNING!

Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.

Driving in Hilly Terrain

WARNING!

Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops or other people or vehicles that may be on the other side of the hill.

If you’re unable to continue up a hill, turn the snowmobile downhill before it loses momentum. If this isn’t possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the parking brake (if equipped). Keeping away from the downhill side of the snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmo bile, restart the engine, release the parking brake, and descend the hill carefully.

19

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.

NOTICE:

Operation of the engine with the belt removed may result in damage to the engine.

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

NOTICE:

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 dynami cally balanced before installation. Any tampering may disrupt this preci sion balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, espe cially 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 steer ing 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.

20

SAFETY Operator Safety

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile.

NOTICE:

Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

WARNING!

Inadequate cooling and lubrication will lead to overheating of the slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the snowmobile so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.

21

SAFETY Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile condi tions 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 driv ers 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 bal ance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they’ve taken a snow mobile safety course and have an operator’s certificate. For their pro tection, 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 pro tection 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 defen sively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile unattended.

22

SAFETY Operator Safety

Windchill/Temperature Charts

5 10 15 20 25 30 35 40 45 50 55 60 The following information is provided to help you determine when tem peratures become dangerous for riding.

WIND CHILL CHART (

F)

Wind Speed in MPH 40 35 30 25 20 15 Actual Thermometer Reading ( _ F) 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature ( _ F) Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 36 34 32 30 29 28 28 27 26 26 25 25 25 21 19 17 16 15 14 13 12 12 11 10 31 27 25 24 23 22 21 20 19 19 18 17 19 15 13 11 9 8 7 6 13 9 6 4 3 1 0 -1 7 3 0 -2 -4 -5 -7 -8 1 -4 -7 -9 -11 -5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91 5 4 4 3 -2 -3 -3 -4 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98 Frostbite in >> 30 min.

10 min.

5 min.

WIND CHILL CHART (

C)

Wind Speed in KPH 5 2 -1 -4 -7 Actual Thermometer Reading ( _ C) -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46 Equivalent Temperature ( _ C) Calm 8 16 24 32 40 48 56 64 72 80 88 96 -6 -7 -7 -7 -8 2 0 -2 -3 -4 -5 -5 -6 -2 -2 -3 -3 -3 5 3 2 1 0 -1 -1 -2 -1 -4 -6 -7 -4 -7 -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 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -8 -9 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77 Frostbite in >> 30 min.

10 min.

5 min.

23

SAFETY Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protec tion. 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 decal.

safety

decals are pro vided by POLARIS at no charge. The part number is printed on the

Clutch Cover Warning

This warning decal is found under the hood on the clutch cover:

WARNING Do not operate with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself. See your dealer.

Pressure Cap Warning

This warning decal is found under the hood on the pressure cap of appli cable liquid cooled models:

WARNING Do not open hot. Test or replace when changing coolant. Press down and turn to release cap. 13 PSI

24

Safety Decals and Locations

Passenger Warning

Snowmobiles designed for an operator and one passenger have a warning decal on the left console. For more information on operating with a passenger, see page 13.

“One Passenger” Warning

WARNING This vehicle is designed for operator and “ONE” passenger only.

Track Warning

WARNING 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.

SAFETY

Track Warning 25

SAFETY Safety Decals and Locations

Reverse Warning Operation Warning

Reverse Warning

POLARIS snowmobiles equipped with electric reverse and will have this decal on the 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 con trol to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

26

SAFETY Safety Decals and Locations

Operation Warning

An operation warning decal is present on the console of all POLARIS snowmobiles:

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 operat ing 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 require ments.

• 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 the engine, check throttle, brake, and steering for proper oper ation. 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.

27

FEATURES

13 14 12 11 10 9 8 7 15 6 5 4 3 2 16 17 18 19 1 1.

Nosepan 2.

3.

4.

5.

6.

Skis Front Bumper (do not use for pulling or dragging the snowmobile) Hood Headlight Windshield 7.

8.

9.

Mirrors Operator Seat Passenger Grab Handle 10. Passenger Seat 11. Backrest 12. Cargo Bag 13. Grab Handle Heater Switch 14. Taillights 15. Rear Bumper 16. Snow Flap 17. Track 18. Passenger Footrest 19. Suspension 28

9 1

FEATURES

2 3 4 10 8 7 6 5 11 12 15 1.

2.

3.

4.

5.

6.

7.

8.

MFD Display Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button MFD Control Headlight Dimmer Switch Parking Brake Lock Brake Lever 14 13 9.

Ignition Switch 10. Heated Windshield Power Plug 11. Engine Stop Switch 12. Throttle Control 13. Hood Hold Down Straps 14. Fuel Filler Cap 15. Rider Select ® 29

FEATURES Backrest

The backrest is adjustable for either operator or passenger use.

1. Loosen the upper adjustment knobs to raise or lower the backrest.

2. Loosen the lower adjustment knobs to move the backrest for ward for operator use or rear ward for passenger use. 3. Always tighten the knobs securely after adjusting.

Adjustable Headlights

Move the adjuster to the left to lower the headlight beam.

Move the adjuster to the right to raise the headlight beam.

Radiator Compartment Access Panel

The access panel is provided for cleaning debris from the radiator.

Raise/Lower Operator/Passenger  30

FEATURES Cargo Bag

The cargo bag is secured to the rear of the tunnel with straps. The cargo bag and the passenger seat are removable to provide open storage for transporting larger items. 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 seat back or the cargo area.

1. Remove the cargo bag.

2. Push down on the seat latch lever, which is located at the lower rear of the passenger seat.

3. Lift up the seat and remove it from the chassis.

4. Reverse the procedure to reinstall the seat. Press down firmly on both sides of the seat to engage the latch. Verify that the latch is engaged by firmly pulling the seat upward.

Cargo Bag Seat Latch 31

FEATURES Passenger Grab Handle

On some models the position of the passenger grab handles can be adjusted for rider preference.

1. Unscrew and remove the knob assemblies that secure the grab handles.

2. Reposition the grab handles to one of the three available posi tions on the grab handle tube between the operator seat and the passenger seat.

3. Reinstall the knob assemblies and tighten securely.

Knob Assembly 32

FEATURES RIDER SELECT Adjustable Steering System

The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions.

WARNING!

If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your POLARIS snowmobile has been engineered for this range of adjustability. Removing this lockout and using RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking. This could lead to loss of control resulting in serious injury or death. Always be sure that the handlebars and brake lever do not contact any other snowmobile components at any steering position AND at any RIDER SELECT position.

Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it. Operation in position 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death.

Choosing the Best RIDER SELECT Position

Position

1 2 3

Riding Style Relaxed Trail Riding

Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding.

4 5

General Trail Riding, Boondocking, Deep Snow Riding

Rider weight is centered on the snowmo bile, providing balance, comfort and con trol for both novice and experienced riders.

This is the recommended position for most riding situations.

6 7

Snowcross/Steep Hill Climbing Only

Rider weight is ahead of the center of the snowmobile, adding weight to the skis and making the snowmobile heavier in the front. These positions are ONLY for snow cross and severe hill climbing.

33

FEATURES RIDER SELECT Adjustable Steering System WARNING!

Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system.

1. Stop the snowmobile.

2. Press the release button and move the handlebar forward or rearward to the desired position.

WARNING!

Do not lubricate the RIDER SELECT mechanism. Doing so could cause loss of control and result in serious injury or death. The RIDER SELECT mechanism is lubricated for life at the factory.

WARNING!

Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. Such accessories could limit your ability to steer the vehicle and/or may contact the brake lever. This could lead to loss of control resulting in serious injury or death. Always be sure that accessories do not contact the handlebar or brake lever at any steering position and at any RIDER SELECT position.

34

FEATURES Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation.

You may notice decreased engine RPM and performance when DET is activated, but in most cases DET activation is temporary, and the timing will return to normal automatically. In extreme conditions the DET sys tem retards timing and holds it in a retarded state. If this occurs, replace the fuel with recommended fuel or see your POLARIS dealer for ser vice.

Cause of DET Activation

Poor quality fuel Improper engine modifications

Solution

Replace with higher quality fuel Do not modify the engine

Sensor Fail-Safe

The DET includes a sensor fail-safe system to prevent the engine from damage if the sensor fails, becomes disconnected or is unable to detect detonation. The rider will experience a loss of power. The sensor must be reconnected or repaired to regain full power. See your POLARIS dealer for service if this occurs.

Tip:

The check engine light will flash six times if the sensor fails or becomes dis connected.

35

FEATURES Instrumentation

MFD Component Identification

Item

1 1 Analog (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 3 4 5 6 7 8

Digital Display Identification

Item

1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers per hour RPM - Engine crankshaft revolutions per minute 4 Air Temp (if equipped) Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1/Trip 2/Trip F Service Label Altitude Label 7 Fuel Level (if equipped) 1 3 4 5 36 6 2 7 2

FEATURES Instrumentation

MFD Settings

The MFD control switch allows you to set the MFD display to your pref erences. The rocker switch has a MODE button (top) and a SET but ton (bottom). Specific instructions are outlined on the following pages.

MODE SET

Standard vs. Metric

The MFD will display either stan dard or metric units of measurement. While viewing a screen that displays measurements (MPH, km/h or tem MFD Control Switch peratures), press and hold the MODE switch until the unit of measure ment changes (about 10 seconds). 37

FEATURES Instrumentation

MFD Settings

Speedometer/Tachometer

The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer read ings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).

To change viewing preferences, press and hold the MODE button for three seconds. When the button is released, the new setting becomes active and screen colors change. See table below.

Option

1 2

Analog Display

Speed RPM

Digital Display

RPM Speed

Analog Screen

Blue “MPH” Red “X100RPM”

Digital Screen

Blue Backlight Red Backlight 38

FEATURES Instrumentation

MFD Digital Display Programs

Press and release the MODE button to cycle through the three MFD pro grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.

Performance Program

The Performance Program automatically displays either speed or tachometer, whichever is opposite the analog display. See page 38. It also displays electrical system voltage and fuel level (if equipped).

While in the Performance mode, press the SET button to cycle through the odometer, Trip 1, Trip 2, Trip F (if equipped with electronic fuel gauge) and Clock (if equipped). Use the following procedures to make changes to these screens.

Odometer Setting

The odometer records the vehicle's total distance traveled since manufacture. The odometer cannot be reset.

39

FEATURES Instrumentation

MFD Digital Display Programs

Trip Settings

Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. Both odometers can be reset to zero.

1. Enter the Performance Program.

2. Press and release the SET button until the desired trip screen is active.

3. Press and hold the SET button for two seconds to reset the trip odometer to zero.

4. Press and release the SET button to cycle through additional screens.

40

Instrumentation

MFD Digital Display Programs

Performance Program Trip Settings

If the snowmobile is equipped with an electronic fuel gauge, Trip F automati cally displays when the fuel level is low. The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank.

The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1/4 tank. The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1/4 tank. The Trip F odometer will automati cally reset to zero after refueling.

FEATURES

41

FEATURES Instrumentation

MFD Digital Display Programs

Performance Program Clock Setting (if equipped)

1. Enter the Performance Program.

2. Press and release the SET button until the clock screen is active.

3. Press and hold the SET button for five seconds.

4. When the hour starts flashing, press the SET switch

once

to advance one hour. (

Press and hold

the SET button to advance the hours quickly.) 5. Press and release the MODE button to save the hour. The minutes will begin flashing.

6. Set the minutes in the same manner.

7. When finished, press and release the MODE button to save the new setting. If the MODE button is not pressed within ten seconds, the gauge will automatically save the new entry.

42

FEATURES Instrumentation

MFD Digital Display Programs

Engine Program

The Engine Program automatically displays the engine coolant tempera ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air temperature will display as additional screens in the engine program. Press the SET button to dis play the ambient air temperature and altitude screens. Use the following procedures to make changes to these screens.

Hour Meter

The hour meter records the total hours of engine operation since manufacture. This meter cannot be reset.

Engine Temperature

A thermometer measures water temperature, giving an indication of engine temperature.

Air Temperature (if equipped)

The MFD displays actual air temperature in either standard or metric units.

1. Enter the Engine Program.

2. Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.

43

FEATURES Instrumentation

MFD Digital Display Programs

Engine Program Altitude (if equipped)

The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment.

1. Enter the Engine Program.

Tip:

Press and hold the MODE switch for ten sec onds to switch between standard and metric units of measurement. When "ALt" displays, the program is in the metric mode.

2. Press and release the SET button until the altimeter screen is active.

3. Press and hold the SET button for five seconds. When the digits begin to flash, release the button. 4. Press and release the SET button

once

to advance 50 feet (15 m).

Tip: Press and hold the SET button to advance quickly by 100-foot (30 m) incre ments.

5. Adjust the altitude display to within 50 ft. (15 m) of current altitude.

Tip:

The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure. The gauge can adjust the displayed altitude to +/- 1300 ft. (396 m) from the preset value. It will adjust up to +1300 ft. (396 m) above the calibrated altitude. Once the +1300 ft. (396 m) offset has been reached, the next adjustment is -1300 ft. (396 m) from the calibrated altitude, and 50 ft. (15 m) will be added to the altitude each time the SET button is pressed.

6. Press and release the MODE button to set the reading at the adjusted value. If the MODE button is not pressed within ten seconds, the gauge will automatically save the new entry.

44

FEATURES Instrumentation

MFD Digital Display Programs

History Program

The History Program automatically displays electrical system voltage level and fuel level (if equipped).

While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval set ting. The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed. The History Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings.

Maximum Speed/Maximum RPM

1. Enter the History Program.

2. Press and release the SET button until one of the two screens is active.

Tip:

The MPH and RPM values are both reset at the same time. Reset the values before each run to obtain accurate readings. 3. Press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM.

Tip:

Due to electrical noise, the MFD may occa sionally display MAX MPH/RPM values that are not representative of actual values.

45

FEATURES Instrumentation

MFD Digital Display Programs

History Program Service Interval Reminder

The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG" will flash in the icon area for five seconds each time the engine is started (until the service reminder is reset.) Use the following procedures to reset the reminder.

To reset the reminder at the existing interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is active.

3. Press and hold the SET button for

ten

seconds, continuing to hold even after the display begins to flash.

4. When the display stops flashing, release the button. The service interval has been reset.

46

FEATURES Instrumentation

MFD Digital Display Programs

History Program Service Interval Reminder

To reset the reminder at a new interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is active.

3. Press and hold the SET button for

five

seconds, until the hours begin to flash. Immediately release the button.

4. Press the button again, up to five times, to advance the reminder in 50-hour increments.

Tip:

The maximum interval is 250 hours.

5. Press and release the MODE button to save the new settings.

To disable the service interval reminder:

1. Press the SET button once after reaching 250 hours on the display. The gauge will display "OFF".

47

FEATURES Instrumentation

MFD Battery Replacement

Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replace ment batteries are available from your dealer.

1. Remove the plenum from the under side of the hood.

2. Locate the black battery compart ment. It has a red wire and a brown wire with a white stripe. It's located about three inches down the main harness from the point where the harness connects to the MFD.

3. Cut the plastic cable tie from the outside of the compartment.

4. Carefully cut the bottom of the compartment (opposite the wires) to separate the heat-sealed seams. Squeeze the corners of the compart ment inward so the battery is visible.

Tip:

Note the orientation of the battery before removing it. An incorrectly installed battery will not maintain the clock.

48

FEATURES Instrumentation

MFD Battery Replacement

5. Using needle-nose pliers, grasp the battery and rotate it so the lead ing edge of the battery is raised away from the battery holder. Pull the battery out gently.

Tip:

The battery will not come out of the holder unless the leading edge of the battery is raised. Hold the battery compartment, not the wires, while remov ing the battery. Pulling on the wires will separate them from the battery holder.

6. Install a new battery with fingers only.

7. Seal the end of the battery compartment using high strength double sided tape between the two compartment halves or high strength single-sided tape around the outside of the compartment.

8. Make sure the taped seam of the compartment faces the downward side of the wire harness.

9. Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located. Make sure the battery wires are not stretched tight.

Gauge Cleaning

1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth.

2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or pro tective rubber boot. Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source.

NOTICE:

To prevent damage to the lens, do not use alcohol for cleaning. Do not allow chemicals or sprays to come into contact with the lens. Immediately clean off any gasoline that splashes on the gauge during refueling.

49

THE PERFECT FIT IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments.

Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The snowmobile should be methodically tested, one change at a time, under the same conditions (trail and snow condi tions, 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 3 2

IFS Adjustment Options

• Front shock spring preload • Optional springs • Optional shock valving 4 50

THE PERFECT FIT IQ Front Suspension Adjustments

Front Shock Spring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres sure. 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 pre load beyond the factory settings, and ensure that both sides are adjusted the same. When decreasing preload, make sure at least two turns of preload are hold ing the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. is fully extended.

Low Preload High Preload Failure to do so could cause the retainer to fall off when the suspension

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.

51

THE PERFECT FIT IQ Front Suspension Adjustments

Shock Valving

The shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness.

WARNING!

Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a POLARIS dealer.

52

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 sus pension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bot tom out harshly on a snow-cross 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.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre load should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred set-up. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a worn 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 suspension lubrication information beginning on page 89.

53

THE PERFECT FIT IQ 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.

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 measure ment X. This is measurement Y.

X 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

IQ Comfort (136)

Recommended Sag

4-5 inches (10-13 cm)

Adjustment

Torsion Spring Preload

See Page

55

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 rat ing are available for some models. Please see your dealer for availability.

54

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 55

THE PERFECT FIT IQ Rear Suspension Adjustments

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 front limiter straps. Tighten the straps to increase ski pressure. Loosen the straps to reduce ski pressure.

Upper Nuts 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.

56

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 suspen sion 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 indepen dence 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.

57

THE PERFECT FIT IQ Rear Suspension Adjustments

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 indepen dent 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) 58

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.

LOW HIGH LOW MEDIUM To decrease weight transfer under acceleration (for improved corner ing), rotate the RRSS to a higher position.

To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.

Tip:

Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride. A scissor stop tool is also available from your dealer.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor rect tension and alignment. Refer to the track tension maintenance sec tion beginning on page 110.

59

THE PERFECT FIT Handlebar Adjustments

Use the RIDER SELECT feature to adjust handlebar position. See page 33. Use the following steps to adjust handlebar angle at the handlebar block.

1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts.

2. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block (turn han dlebar to left or right for access to back nuts).

Handlebar Cover

Tip:

If necessary, pry the blocks apart with a screwdriver.

3. Adjust the handlebar to the desired height. Be sure han dlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right.

Nuts Adjuster Block Bolts 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.

60

THE PERFECT FIT Accessories

POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.

Use only POLARIS parts and accessories on your POLARIS snowmo bile. 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. Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service.

61

THE PERFECT FIT Traction Products

Studs

Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products.

Use only POLARIS traction products on your snowmobile. Track war ranties are void if track damage or failure results from improper or excessive stud installation or the use of non-POLARIS traction prod ucts.

See your dealer about installing studs and/or carbides.

NOTICE:

Always install wear strips before installing studs. Failure to install wear strips may result in cooler or tunnel damage. See page 63.

Never add shims to the wear strip. Track damage will result because of lack of clearance between upper carrier wheels and track.

Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel.

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering abil ity may be reduced on hard-packed snow or ice.

When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are avail able. See your dealer.

NOTICE:

Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8" (2.86 cm) from the outside edge of the track.

62

THE PERFECT FIT Traction Products

n

Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 115.

If your snowmobile has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used.

Install the appropriate wear strip kit. See your dealer.

Wear strips are designed for a specific stud length. See your dealer's studding chart for recommended traction accessories.

NOTICE:

Whenever wear strips are relocated, be sure there's adequate stud clearance to the heat exchangers. Lack of clearance may result in damage to heat exchangers.

63

PRE-RIDE INSPECTIONS Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items.

Item

Drive Belt Condition Steering System Recoil Rope Parking Brake Lock/Brake Lever/Brake System Throttle Lever Throttle Safety Switch Auxiliary Shut-Off Switch (Engine Stop Switch) Ignition Switch Taillight/Brakelight/Headlight Coolant Level Chaincase Oil Level Injection Oil Level Suspension Mounting Bolts Skags (Wear Bars) Ski Saddle and Spindle Bolts Hood Straps/Latches Seat Latches Rear Wheel Idler Bolts Track Alignment/Condition Rail Slide Condition

See Page

105 66 65 67, 68, 100 65 65 71, 81 71, 81 71 96 90 77 70 63, 115 70 66 65 70, 111 69, 112 112 64

PRE-RIDE INSPECTIONS Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation.

WARNING!

Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.

n

Throttle Lever

The throttle and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle position without binding or hesitation. If the throttle does not func tion smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately.

n

Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated. See page 78 for procedure.

n

Seat Latches

Ensure that the seat latches are securely in place before every use of the snowmobile.

n

Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement.

65

PRE-RIDE INSPECTIONS Before Starting the Engine

n

Hood Latches

The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile.

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Steering System

WARNING!

Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

If your snowmobile is equipped with RIDER SELECT, perform this check in both the full up and full down steering positions.

66

PRE-RIDE INSPECTIONS Before Starting the Engine

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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 infor mation on page 102.

1/2" (1.3 cm)

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 101.

Check for the presence of air in the fluid system. See page 102 for more information, or see your dealer for service.

WARNING!

Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes serviced at the first sign of sponginess.

67

PRE-RIDE INSPECTIONS Before Starting the Engine

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Parking Brake Lever Lock

Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/Cover 4. Fluid Level Indicator 1 2 3 4

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 parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running. It will also be lit when the service brake is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.

WARNING!

If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.

68

PRE-RIDE INSPECTIONS Before Starting the Engine

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Track Inspection

WARNING!

Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle.

WARNING!

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.

Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

69

PRE-RIDE INSPECTIONS Before Starting the Engine

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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 follow ing items on a weekly basis or before any long trip.

Item

Suspension mounting bolts Rear idler wheel bolts Rear idler adjusting bolt locknuts Torque arm bolts Carrier and bogie wheel bolts Front torque arm limiter strap Rail slide Track All rear suspension components Ski runner/skag Ski spindle bolts Tie rod end nuts

Check

Tightness Tightness Tightness Tightness Tightness Condition Condition Tension Lubrication Condition Tightness Tightness

Page

- 111 - - - - 112 110 88 - - - 70

PRE-RIDE INSPECTIONS Start the Engine and Check

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Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.

n

Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

n

Lighting

Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

n

Mirror Adjustment

If equipped, adjust your mirrors so they can be used to their full advan tage.

n

Tether Switch (if equipped)

If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

n

Operating Area

Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.

71

OPERATION Break-In Period

Engine Break-In

Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel as outlined below. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.

First Tank of Fuel: After Break-in: Oil Recommendations

POLARIS Premium 2-Cycle Semi-Synthetic Oil POLARIS VES Gold Plus Oil

Tip:

The semi-synthetic oil will seat the rings faster than the VES Gold Plus oil.

See page 118 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.

Initial Fuel Premix

Always premix fuel in 5-gallon (19-liter) increments in a separate fuel container. Never add oil directly to the fuel tank.

Fuel

Each 5 gal. (19 l)

Semi-Synthetic Oil

16 oz. (473 ml)

Ratio

40:1 72

OPERATION Break-In Period

Engine Break-In

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 vehicle speeds to reduce friction on all close-fit ting machined parts, allowing them to break in slowly without damage.

NOTICE:

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 snow mobile.

Oil Injection System

Always check and fill the oil tank when refueling. See page 77.

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.

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 that feature a sanded finish should be first 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 engag ing throttle.

73

OPERATION Slide Rail and Track Cooling NOTICE:

Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads.

Track Warm-Up WARNING

A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable.

WARNING

Use of traction products such as studs, ice growsers, etc. will increase the possi bility 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 snow mobile at the rear bumper. The track should be approximately 4" (10 cm) off the ground.

2. Start the engine and allow it to warm up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several revolutions.

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 snowmobile to the ground.

5. Grasp the skis by their front loops and move them from side to side to loosen snow and ice.

74

OPERATION Fuel Safety 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 refu eling 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.

WARNING

The engine exhaust from this product contains chemicals known to cause can cer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

75

OPERATION Fuel

For peak performance, POLARIS recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor mance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel.

Do not use fuel containing more than 10% ethanol (including E85)

.

NOTICE:

Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended.

Prolonged exposure to petroleum based products may damage paint. Always protect painted surfaces when handling fuel.

Fuel System Deicers

If you use non-oxygenated fuel, POLARIS recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

Never use deicers or additives containing methanol.

POLARIS also recommends the use of Carbon Clean Plus. See page 118 for the part numbers of POLARIS products. If you use oxygenated fuel containing ethanol, additional alcohol deic ers or water absorbing additives should not be used.

76

OPERATION

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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 recom mended oil before further operation. See page 72 for oil recommenda tions.

Visually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank. If oil is not visible, continued opera tion may cause serious engine damage.

Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. They 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.

Always maintain the oil level above the tank’s low level line. This is especially important when the snowmobile is operated in mountainous terrain. Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage.

NOTICE:

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of POLARIS 2-cycle oils for your snowmobile. Never mix brands.

Operating the snowmobile without proper engine lubrication can result in serious engine damage. Always check the oil level when refueling.

Low Oil Level

Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add the recommended oil to the tank. The POLARIS oil cap on the oil bottle is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

77

OPERATION

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Engine Stop Switch

Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting.

Stop Switch n

Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

WARNING!

Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident. If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

78

OPERATION

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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 throttle body to determine what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times. The lever and cable must return to the idle position quickly and completely.

4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures.

5. If the engine doesn't start, take the snowmobile to an authorized POLARIS dealer for service.

Tip:

Excessive freeplay in the throttle cable may cause the safety switch to acti vate, preventing the engine from starting. If this occurs, return the snowmo bile to an authorized POLARIS dealer for service.

Tip:

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.

79

OPERATION Electronic Reverse (PERC)

Electronic reverse will activate only if the engine RPM is below 4000 .

WARNING!

speed.

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle • Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle.

• Look behind the snowmobile before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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.

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your snowmobile is clear.

3. Push the yellow reverse button on the left-hand control for one second, then release.

Reverse Button

Tip:

A reverse light on the instrument panel will indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in reverse.

Tip:

If the engine stops running, the transmission will be in forward gear when it's restarted.

80

OPERATION Electronic Reverse (PERC)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut off.

3. Apply the throttle slowly to make sure the transmission is in for ward.

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Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 78 for more information about the engine stop switch.

SYSTEM

Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (Option)

WHAT IT DOES

Interrupts ignition circuit Slows jackshaft Interrupts ignition circuit Interrupts ignition circuit Interrupts ignition circuit 81

OPERATION Daily Storage

At the end of each ride, park the snowmobile on a level surface and sup port it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

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.

82

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 con trol information (ECI) label and a factory-installed emissions informa tion 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 avail able to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi ble 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.

83

MAINTENANCE POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out lined in this manual. Record maintenance and service in the Mainte nance Log beginning on page 133.

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 per formed by a qualified service technician. For continued optimum perfor mance 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 regis tered 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 adjust ments 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 comfort able 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.

84

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

150 mi.

(240 km) 500 mi.

(800 km)

CLUTCH I Frequency

1000 mi.

(1600 km) 2000 mi.

(3200 km)

I I

Clutch Alignment Offset (without belt) Drive Belt Condition Clutches Belt Tension Clutch Sheaves Engine Mounts Recoil Rope Engine Torque Stop Cylinder Head Bolts Cylinder Base Nuts Ignition Timing BTDC VES System Coolant Coolant Hose Heat Exchangers Coolant Circulation Coolant Leaks Spark Plug Condition Exhaust Pipe Exhaust Retaining Springs 104 105 104 - 104 - - 107 - - - - 96 - 98 - - 92 95 95

I C I I ENGINE/COOLING I I I I I I I I I C I I I I I I I I I C I I I I I I I I I I I I I C I

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

I C I I I I I I I I C R I I I I R I I

Pre Season

I I I I I I I I I I I I I I

85

MAINTENANCE Periodic Maintenance Interval Table Item

Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Throttle Position Sensor Fuel Lines Fuel Filter Oil Filter Oil Lines Air Box

See Page

- - - 100 - 68 67, 100 101 150 mi.

(240 km) 500 mi.

(800 km)

BRAKES I I I I I I

- 65, 79

FUEL MANAGEMENT I I I

--

I Frequency

1000 mi.

(1600 km) 2000 mi.

(3200 km)

I I I I I I I I I I I I I I I I I I I

89 - 94 94 95 95 - 71, 78

L I L I L I

Pre Season

I I I I I I R - Every 2000 mi. (3200 km) or Every 2 years I I ELECTRICAL R I I R I I I I I I I I I

Auxiliary Shut-Off Switch Throttle Safety Switch Ignition Switch Taillight Brakelight Headlight 78 - 71 71 71

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

86

MAINTENANCE Periodic Maintenance Interval Table Item

Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fas teners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearing Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Drive Chain Tension Hood Latches Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot Shafts Steering Post U-Joint Camber Alignment Handlebar Centering Tether Switch and Strap Track Alignment Track Tension Front Limiter Strap Rail Slide Condition Chaincase Oil

See Page

- - - - - - 89 116 115 - 99 66 111 111 88 - - - 71 112 110 - 112 90 150 mi.

(240 km) 500 mi.

(800 km)

CHASSIS I I I Frequency

1000 mi.

(1600 km) 2000 mi.

(3200 km)

I I I I I I I I I I I I I I I I I I I I I I I I I L I I I I L L I I L I I L L I I I I I I I I I I L L I I I I I I I I I I I I I I I I I I L L I I I R

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Pre Season

I I I C I I I I I L I I I I L I I I I I I I

87

MAINTENANCE Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS Premium All Sea son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 85 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 sus pension. For more information about suspension lubrication and adjust ments, see your POLARIS dealer.

IQ Comfort Rear Suspension

    88

MAINTENANCE Lubrication

Driveshaft Bearing

Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

Throttle Cable

Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.

Fitting

Front Suspension

The front suspension and steering components do not require lubrica tion.

89

MAINTENANCE

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Chaincase Oil

Check the chaincase oil level at the intervals outlined in the Periodic Main tenance Table beginning on page 85.

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 chain case 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 118 for the part numbers of POLARIS products.

Oil Check

1. Position the vehicle on a level sur face.

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.

3 1 2 90

MAINTENANCE 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 4. Install a new sealing washer on the drain plug. The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

6. Remove the fill plug. Clean off all metal shavings from the plug.

7. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.

8. Reinstall the fill plug, making sure it is seated properly.

91

MAINTENANCE Spark Plugs

A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.

NOTICE:

Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile.

• Use recommended spark plugs with the proper gap. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. If a plug is fouled, replace the plug with a new plug.

CAUTION!

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

92

MAINTENANCE Spark Plugs Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi cates the proper type and heat range for the engine and the service.

Tip:

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 Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil or use of non-recommended injection oil.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Reinstall the spark plug cap.

93

MAINTENANCE Intake Filters

The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow.

Fuel Injectors

All fuel injector service must be performed by an authorized POLARIS dealer. Do not attempt to clean or service the fuel injectors.

Fuel Pump

All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.

Fuel Filter

See your POLARIS dealer for replacement of the fuel filter at the inter vals outlined in the Periodic Maintenance Table beginning on page 85.

Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals, the filter may need replacement. See your dealer.

Fuel Lines

Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete rioration 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.

94

MAINTENANCE 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 fil ter.

Exhaust System

Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 85.

CAUTION!

the exhaust system to cool. Never perform this procedure with the engine running.

Hot exhaust system parts can cause burns. Allow adequate time for 1. Allow the engine and exhaust system to cool completely.

2. Open the hood.

3. Inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

4. Replace any damaged or missing components.

5. Close the hood.

95

MAINTENANCE Cooling System

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper ated at extremely low temperatures, greater protection may be required. Please see your POLARIS dealer. When adding or changing coolant, POLARIS recommends using Pre mium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 118 for the part numbers of POLARIS products.

Tip:

Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

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Coolant Level

The engine coolant level is controlled by the recovery system. The recovery system components are: • Coolant reservoir bottle • Filler neck • Pressure cap • Connecting hoses Always maintain the coolant level at the “COLD FILL” mark on the coolant overflow tank (when the engine is cold).

NOTICE:

Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage. Always maintain the coolant level as recommended.

96

MAINTENANCE Cooling System

Coolant High Temperature Indicator Light

The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indi cator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service. Add coolant if the level is low. Engine performance will be reduced if you continue operating when the high temperature light is on.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your snowmobile.

97

MAINTENANCE Cooling System

Bleeding the Cooling System

CAUTION!

Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part.

NOTICE:

If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.

Perform the bleeding procedure when the engine is cold.

1. Position the vehicle so that the top of the tunnel is level. Elevate the front of the vehicle slightly if necessary.

2. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark.

3. Remove the bleed screw from the water outlet manifold and/or the thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

4. Add coolant to the coolant bottle to the maximum mark.

5. Start the engine and run at a fast idle for two to three minutes. Loosen the bleed screw occasionally to purge any trapped air.

6. Stop the engine and check the coolant bottle level. Fill as required.

7. Feel the heat exchangers under the running boards. If the system is bled properly, they'll be warm to the touch. If they're not, repeat step 5. Lift the front of the machine slightly to assist in the bleeding.

8. Replace the pressure cap and carefully lower the front end of the machine.

98

Drive Chain Tension

Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counter clockwise 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.

MAINTENANCE

2 99

MAINTENANCE Brakes

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Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 67.

Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail able for replacing brake pads. See your dealer.

WARNING!

Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety. Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive. Always replace brake pads when the brake pad material becomes thinner than the backing plate, approximately 1/16" (1.5mm).

Brake Components

1. Brake Caliper 2. Brake Disc 3. Brake Pad Material (Replace when thickness is less than 1/16 I /1.5 mm).

Excessive Lever Travel

Hydraulic brakes are self adjusting, but if excessive brake pad clearance develops bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment.

2 3 1 100

MAINTENANCE Brakes

n

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.

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.

NOTICE:

Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately.

Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 118 for the part numbers of POLARIS products.

Sight Glass The brake fluid level can be seen through the fluid level indicator (a plastic sight glass) in the master cyl inder reservoir. If the fluid is suffi cient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid.

101

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 possi ble. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX marks or 1/4"-5/16" (.6-.8 cm) below the lip of the reservoir open ing. 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 101. 8. Reinstall the gasket and cover.

102

MAINTENANCE Lights

Removing Halogen Bulbs

Tip:

Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi due, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel.

1. Remove the plenum cover ing from the headlight assembly.

2. Lift the rubber boot to expose the bulb.

3. Push down on the spring to release it from the housing.

4. With the wire harness attached to the bulb, with draw the bulb from the housing.

Harness Spring Bulb 5. Grasp the bulb by its metal base and carefully separate the bulb from the harness.

Installing Halogen Bulbs

1. Hold the bulb by its metal base and install it into the wire harness.

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. Adjust headlight aim. See page 30.

Replacing Taillight Bulbs

1. Remove the screws securing the taillight lens. Remove the lens.

2. Push the bulb inward and turn it counterclockwise to remove it.

3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it.

4. Reinstall the taillight lens.

103

MAINTENANCE Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.

WARNING!

If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made.

WARNING!

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.

NOTICE:

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 perfor mance. See your dealer for service and adjustments. A special tool is required to check for proper alignment.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer.

104

MAINTENANCE Clutch System

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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 123.

For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. n

Drive Belt Deflection

Measure belt deflection with both clutches at rest and in their full neutral position.

Place a straight edge on the belt and apply downward pressure while measuring at point A. This measurement should be 1 1/4" (3.2 cm).

Measure A Straight Edge

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 106). Turn the wrench clockwise

slightly

to remove pressure from the sheaves.

2. Loosen the 7/16" jam nut on the belt width adjuster.

3. Using a 1/8" Allen wrench, adjust the threaded set screw as needed.

Tip:

Turn the set screw in (clockwise) to increase the distance between the sheaves and out (counterclockwise) to decrease the distance.

4. Tighten the jam nut.

105

MAINTENANCE Clutch System

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 operat ing 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. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.

7. Locate the L-wrench in the tool kit. Install the wrench into the open threaded hole in the outer sheave of the clutch (  ).

8. Turn the wrench clockwise until the sheaves open far enough to remove the belt. If the wrench does not turn readily, rotate the driven clutch counterclockwise an additional 1/4 turn by hand and try again.

9. Grasp the belt at the lower edge and remove it.

106

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 cir cumference 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 read justing 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 wrench.

4. Reinstall the side panel.

5. Close and secure the hood.

6. Break in the new belt. See page 73.

Torque Stop

Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010

I .030

I (.25-.75 mm) from the engine case. Adjust if necessary. Lock the jam nut.

.010

I -.030

I (.25-.75 mm) 107

MAINTENANCE Track Replacement

When replacing the track, always install a track having the lug size rec ommended for your model. See your POLARIS dealer.

NOTICE:

Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.

Track Inspection WARNING!

Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift and sup port the rear of the snowmobile off the ground.

2. Rotate the track by hand to check for damage.

3. Carefully examine the track along the entire length of each rod. Bend the track to check for break age. 4. Replace the track if any rod dam age is found.

Rods 108

MAINTENANCE Track Lubrication WARNING!

lubrication.

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 The slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear.

Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty.

NOTICE:

High speed use on hard-packed surfaces is not recommended for models equipped with a deep lug track. Track lug damage may occur. Keep high speed use to a minimum, including frequent slow-speed intervals for track cooling.

109

MAINTENANCE Track Tension WARNING!

running.

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 Track adjustment is critical for proper handling. Always maintain cor rect tension and alignment.

TRACK TENSION DATA CHART Suspension

IQ Comfort

Slack Measurement

7/8"-1 1/8" (2.2-2.9 cm)

Weight

10 lbs. (4.54 kg)

Measurement Location

16" (40 cm) ahead of rear idler shaft

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 snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of the rear idler wheel.

Tip:

Measure at the point where the weight is hanging.

110

MAINTENANCE Track Tension

4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt.

6. Loosen the lock nuts.

Lock Nut Adjusting Screw Slack Measurement Shaft Bolt  16 I (40 cm) 10 lbs. (4.54 kg) 7. Tighten or loosen the track adjusting screws as necessary 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 snowmobile is new.

9. Start the engine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).

10. Check track alignment (see page 112) and adjust as necessary.

11. Tighten the lock nuts.

12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).

111

MAINTENANCE

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Track Alignment

Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.

1. Safely support the rear of the snowmobile with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns slowly at least five com plete revolutions. Stop the engine and let the track come to a stop (do not apply brakes). Rails 3. Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left, loosen left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten locknuts and torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

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Rail Slide Wear

For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum per missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or rails.

Minimum Thickness Replace when worn to top of groove 112

Steering System

Steering Inspection and Adjustment

MAINTENANCE

Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.

     113

MAINTENANCE Steering System

Ski Alignment

WARNING!

Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer.

With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. The measurement between the skis at point X should be 1/8" to 1/4" (3-6 mm) greater than the measurement at point Y.

Tip:

If the skis are misaligned, we recommend that your dealer correct the align ment, since camber adjustment may also be affected.

X

10 in. (25.4 cm) 10 in. (25.4 cm)

Y

114

MAINTENANCE Steering System

n

Ski Skags

WARNING!

ice.

Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or Check skags before each use of the snowmobile to ensure positive steer ing characteristics. Skags must be replaced when worn to half their orig inal diameter.

Tip:

Carbide skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

Some models are equipped with single skags. Some models are equipped with dual skags.

1. Raise and support the front of the snowmobile so the skis are approximately 6" (15 cm) from the ground.

2. Remove the attaching nuts and pry the skag downward.

3. Remove the front end of the skag.

4. Remove the rear end of the skag.

5. Reverse the steps to install a skag.

Skag 115

MAINTENANCE 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 118 for the part numbers of POLARIS products.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint).

The snowmobile should be stored in a dry garage or shed, out of direct sunlight, and covered with a fabric snowmobile cover. Plastic tarp may cause condensation to form and damage snowmobile components.

Controls and Linkage

Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 85.

Bearings

Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All-Season Grease or a similar high quality grease to prevent corrosion.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the service manual. See your dealer.

116

MAINTENANCE Extended Storage

Engine Protection

Proper preparation of the engine and fuel system is vital to the preven tion 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.

Electrical Connections

Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

Track and Suspension

Moderate track tension should be maintained during summer storage. The snowmobile should be supported off the ground to allow the track to hang freely. See illustration.

Transporting the Snowmobile

Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly.

2. Always tie the snowmobile to the transporting unit securely using suitable straps.

3. Remove the ignition key to prevent loss.

117

POLARIS PRODUCTS Part No.

2870791 2875035 2875036 2875038 2877882 2877883 2877884 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890

Description Engine Lubricants

Fogging Oil (12 oz. Aerosol) Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l) VES Gold Plus 2-Cycle Oil (qt./.95 l) VES Gold Plus 2-Cycle Oil (gal./3.8 l) VES Gold Plus 2-Cycle Oil (2.5 gal./9.5 l)

Chaincase Lubricants

Synthetic Chaincase Lubricant (qt./.95 l) Synthetic Chaincase Lubricant (12 oz./355 ml)

Grease/Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz./89 ml) Premium All Season Grease (3 oz./89 ml cartridge) Premium All Season Grease (14 oz./414 ml cartridge) Dielectric Grease (Nyogel ™ )

Coolant

Anitfreeze, 60/40 Premix (gal./3.8 l) Anitfreeze, 60/40 Premix (qt./.95 l)

Additives/Miscellaneous

Carbon Clean Plus Fuel Stabilizer DOT4 Brake Fluid Engine Degreaser Isopropyl Brake and Clutch Cleaner Carb and Throttle Body Cleaner 118

Engine Troubleshooting 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 oper ating RPM during acceleration or load variations Harsh drive clutch engagement Drive belt turns over Machine fails to move Drive clutch binding Driven clutch mal function • SEE YOUR DEALER.

• SEE YOUR DEALER.

Drive belt worn or too narrow Excessive belt/ sheave clearance Wrong belt for appli cation • Replace the drive belt.

Clutch alignment out of spec • SEE YOUR DEALER.

Engine mount bro ken or loose Clutch jammed Track jammed • Replace the drive belt.

• SEE YOUR DEALER.

• Inspect and replace. SEE YOUR DEALER.

• Check for twisted belt or broken spring. SEE YOUR DEALER.

• 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.

119

TROUBLESHOOTING Engine Troubleshooting Problem

Noise in drive sys tem Poor low RPM per formance Engine doesn't turn

Probable Cause Solution

Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro ken Worn drive belt Excessive belt/ sheave clearance Loose torque stop Sticky clutch Poor fuel quality Seized engine Hydrostatic lock • SEE YOUR DEALER.

• SEE YOUR DEALER.

• Inspect and replace as needed.

• Inspect and adjust (or replace).

• SEE YOUR DEALER.

• Inspect and replace as needed.

• SEE YOUR DEALER.

• Inspect and adjust.

• SEE YOUR DEALER.

• Use 87-91 octane fuel (or higher).

• SEE YOUR DEALER. Seizure is a result of poor lubrication, inade quate fuel supply, broken parts or improper cooling.

• 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.

120

Engine Troubleshooting TROUBLESHOOTING Problem Probable Cause Solution

Engine turns but fails to start Faulty ignition Engine lacks power Engine continually backfires No fuel to engine Poor engine com pression Fouled or defective spark plug(s) Fuel filter (loss of high RPM power) Incorrect clutching Faulty plug(s) Fuel System • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER.

• Make sure the fuel valve is on.

• Make sure the fuel tank contains fuel.

• Ice may be in the fuel line, filter or pump. Add isopropyl alcohol to the fuel system.

• Mixture is too lean. A main jet that is too small will cause seizure result ing in loss of power. This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER.

• Replace the plug(s).

• SEE YOUR DEALER.

• SEE YOUR DEALER.

• Change plug(s).

• Dirt or ice may be in the fuel system (deicer should be added to non-etha nol fuel at all times for assurance against fuel line icing).

• SEE YOUR DEALER.

Engine requires more than normal pulls to start Engine backfires but fails to start Incorrect throttle freeplay or faulty switch Poor fuel Not enough fuel get ting to engine Spark plug wires may be on wrong cylinder • Replace with fresh winter fuel.

• SEE YOUR DEALER.

• Reinstall spark plug wires to the cor responding cylinder.

121

TROUBLESHOOTING IQ Comfort Suspension Troubleshooting Problem

Rear suspension bot toms too easily Rides too stiff in rear Machine darts from side to side Front end pushes Steering is heavy

Solution

• Adjust torsion spring preload to achieve proper static sag (see page 54).

• Change torsion spring to stiffer optional spring (see your dealer).

• Rotate RRSS to higher position (see page 59).

• Check for binding suspension shafts and grease all pivot points.

• Adjust torsion spring preload to achieve proper static sag (see page 54).

• Change torsion spring to softer optional spring (see your dealer).

• Check track tension (see page 110).

• Rotate RRSS to lower position (see page 59).

• Check ski alignment (see page 114).

• 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 54).

• Check rail slide/replace if worn (see page 112).

• Install Accu-Trak dual skags (see your dealer).

• 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 54).

• Install single skag (see your dealer).

• Increase IFS preload (if equipped) (see page 51).

• Rotate RRSS to higher position (see page 59).

• Make sure spindles and all steering components turn freely.

• Check ski alignment (see page 114).

• Check skags and skis for damage.

• Set static sag (see page 54).

122

TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution

Driving at low RPM Insufficient warm-up Towing at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection.

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.

Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.

Lower the gear ratio. Reduce RPM. Avoid riding in high ambient temperatures. Check for snow ingestion.

Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engage ment Wrong or missing belt Improper break-in 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.

Check for fouled plugs or water, ice, or dirt in the gas tank or fuel line.

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.

Inspect clutch components. See your dealer.

Use fast, aggressive throttle to engage clutch.

Always use the recommended belt.

Always break in a new belt and/or clutch by avoiding aggressive or high speed operation during the break-in period.

123

WARRANTY Service And Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the POLARIS warranty infor mation 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 mainte nance, 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 124

Service And Warranty Information

POLARIS Anti-Theft System

WARRANTY

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 125

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, dur ing 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 entitle ment. 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 set-up of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer set-up will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship. The warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. The warranty also does not cover any snowmobile that has been structurally altered, neglected, improperly maintained, used for racing or used for pur poses other than for which it was manufactured. The warranty does not cover any dam ages 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, CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARIS ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CON SEQUENTIAL, 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.

126

WARRANTY Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES 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 pro gram, 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 rec ommend the use of POLARIS engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.

127

WARRANTY Conditions and Exclusions

In order to qualify for warranty, the product must have been properly set up and tested by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehi cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con sumer 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 dur ing 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 con sideration 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 128

WARRANTY 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.

129

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA TION.

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 per sonnel 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, War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the selling dealer’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

If You Move:

If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Vehicles importa tion 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 war ranty or service bulletin coverage of any kind, other than ranty.)

safety

bulletins. (Vehicles reg istered 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 war-

For questions call POLARIS Customer Assistance (see page 124).

130

U.S.A. EPA Emissions Limited Warranty

WARRANTY

This emissions limited warranty is in addition to the POLARIS standard limited war ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur chased, 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 kilo meters (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 vehi cle’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 war ranty 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 emis sions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for evaporative emis sions: • 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.

131

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 WAR RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY 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 PUR POSE. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 incon sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman ship.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 con trol 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 vehi cle. 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.

132

MAINTENANCE LOG

Present this section of your manual to your dealer each time your snow mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.

DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi.

(240 km) 500 mi.

(800 km) 1000 mi.

(1600 km) 1500 mi.

(2400 km)

133

MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

134

MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

135

INDEX A

Access Panel, Radiator Compartment 30 Accessories . . . . . . . . . . . . . . . . . . . 61 Adjustable Steering System. . . . . 33-34 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches. . . . . . . . . . . . . . . . . . . . 17

B

Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery Replacement, MFD . . . . . . . 48 Brake Components. . . . . . . . . . . . . 100 Brake Fluid . . . . . . . . . . . . . . . . . . 101 Brake Inspection . . . . . . . . . . . . . . 100 Brake Lever Feel . . . . . . . . . . . . . . . 67 Brake Lever Travel . . . . . . . . . 67, 100 Brake System Bleeding . . . . . . . . . 102 Brakes . . . . . . . . . . . . . . . . 67, 100-102 Break-In Period . . . . . . . . . . . . . . 72-73 Bulbs, Replacing . . . . . . . . . . . . . . 103

C

Cargo Bag . . . . . . . . . . . . . . . . . . . . 31 Cargo Overload . . . . . . . . . . . . . . . . 14 Chaincase Oil. . . . . . . . . . . . . . . . 90-91 Clutch Alignment Offset . . . . . . . . 104 Clutch Center Distance . . . . . . . . . 104 Clutch Cover Warning. . . . . . . . . . . 24 Clutch System . . . . . . . . . . . . . 104-107 Clutches . . . . . . . . . . . . . . . . . . . . . . 20 Coolant. . . . . . . . . . . . . . . . . . . . . . . 96 Coolant High Temperature Light. . . 97 Coolant Level. . . . . . . . . . . . . . . . . . 96 Cooling System . . . . . . . . . . . . . . 96-98 Cooling System Bleeding . . . . . . . . 98 Cooling System Flushing. . . . . . . . . 97

D

DET . . . . . . . . . . . . . . . . . . . . . . . . . 35 Detonation Elimination Technology 35 Digital Display. . . . . . . . . . . . . . . . . 36 Disabled Operators . . . . . . . . . . . . . 14 Drive Belt. . . . . . . . . . . . . . . . . . . . . 20 Drive Belt Adjustment. . . . . . . . . . 105 Drive Belt Break-In . . . . . . . . . . . . . 73 Drive Belt Condition . . . . . . . . . . . 105 Drive Belt Deflection. . . . . . . . . . . 105

D

Drive Belt Installation . . . . . . . . . . . 107 Drive Belt Removal. . . . . . . . . . . . . 106 Drive Chain Tension . . . . . . . . . . . . . 99 Driver Awareness . . . . . . . . . . . . . . . 16 Driveshaft Bearing Lubrication. . . . . 89 Driving Downhill . . . . . . . . . . . . . . . 18 Driving in Hilly Terrain . . . . . . . . . . 19 Driving on Slippery Surfaces . . . . . . 19 Driving Responsibly . . . . . . . . . . . . . 22

E

Emission Control Information. . . . . . 83 Emission Control Label. . . . . . . . . . . 83 Emission Control Maintenance . . . . . 83 Emissions Limited Warranty. . 131-132 Engine Break-In . . . . . . . . . . . . . 72-73 Engine Stop Switch . . . . . . . . . . . . . . 78 Environment, Preservation . . . . . . . . . 6 Exhaust System . . . . . . . . . . . . . . . . . 95 Eye Protection . . . . . . . . . . . . . . . . . . 12

F

Front Rear Scissor Stop. . . . . . . . . . . 57 Front To Rear Coupling . . . . . . . . . . 57 FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 94 Fuel Injectors. . . . . . . . . . . . . . . . . . . 94 Fuel Lines . . . . . . . . . . . . . . . . . . . . . 94 Fuel Pump . . . . . . . . . . . . . . . . . . . . . 94 Fuel Safety . . . . . . . . . . . . . . . . . . . . 75 Fuel System Deicers . . . . . . . . . . . . . 76

G

Gauge Cleaning. . . . . . . . . . . . . . . . . 49 Grab Handle Adjustment. . . . . . . . . . 32

H

Handlebar Adjustments. . . . . . . . . . . 60 Headlight Adjusting . . . . . . . . . . . . . 30 Helmet . . . . . . . . . . . . . . . . . . . . . . . . 12 High Temperature Indicator Light . . 97 Hood Latches . . . . . . . . . . . . . . . . . . 66 136

I

Ice and Snow Build-up . . . . . . . . . . . 18 IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Instrumentation . . . . . . . . . . . . . . 36-49 Intake Filters . . . . . . . . . . . . . . . . . . . 94 Intake Silencer . . . . . . . . . . . . . . . . . 20

L

Lamps, Replacing . . . . . . . . . . . . . . 103 Light, High Temperature Indicator. . 97 Lights . . . . . . . . . . . . . . . . . . . . . . . 103 Limiter Strap Position, SwitchBack . 56 Low Oil Indicator Light . . . . . . . . . . 77 Lubrication . . . . . . . . . . . . . . . . . 88-89

M

Maintenance Interval Table . . . . 85-87 Maintenance Program . . . . . . . . . . . . 84 Maneuverability . . . . . . . . . . . . . . . . 20 MFD Battery Replacement . . . . . 48-49 MFD Components. . . . . . . . . . . . . . . 36 MFD Digital Display Programs . 39-47 MFD Settings . . . . . . . . . . . . . . . 37-38

N

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6

O

Oil Filter . . . . . . . . . . . . . . . . . . . . . . 95 Oil Indicator Light . . . . . . . . . . . . . . 77 Oil Injection System . . . . . . . . . . . . . 73 Oil Level . . . . . . . . . . . . . . . . . . . . . . 77 Oil Lines . . . . . . . . . . . . . . . . . . . . . . 95 Oil Recommendations. . . . . . . . . . . . 72 Operating in Deep Snow. . . . . . . . . . 21 Operation Warning . . . . . . . . . . . . . . 27

P

Parking Brake Lever Lock . . . . . . . . 68 Passenger Warning . . . . . . . . . . . . . . 25 Polaris Products . . . . . . . . . . . . . . . 118 Pre-Ride Checklist . . . . . . . . . . . . . . 64 Pressure Cap Warning . . . . . . . . . . . 24

INDEX R

Rail Slide Wear . . . . . . . . . . . . . . . 112 Rear Rear Scissor Stop . . . . . . . . . . . 58 Rear To Front Coupling . . . . . . . . . . 58 Recoil Rope . . . . . . . . . . . . . . . . . . . 65 Reverse Operation . . . . . . . . . . . 80-81 Reverse Warning . . . . . . . . . . . . . . . 26 Rider Capacity . . . . . . . . . . . . . . . . . 13 RIDER SELECT . . . . . . . . . . . . 33-34 RRSS . . . . . . . . . . . . . . . . . . . . . . . . 58

S

Safety . . . . . . . . . . . . . . . . . . . . . . 8-23 Safety Decals . . . . . . . . . . . . . . . 24-27 Safety Symbols. . . . . . . . . . . . . . . . . . 8 Seat Latches . . . . . . . . . . . . . . . . . . . 65 Shock Valving . . . . . . . . . . . . . . . . . 52 Signal Words . . . . . . . . . . . . . . . . . . . 8 Skags . . . . . . . . . . . . . . . . . . . . 63, 115 Ski Alignment. . . . . . . . . . . . . . . . . 114 Ski Pressure . . . . . . . . . . . . . . . . . . . 56 Slide Rail and Track Cooling . . . . . . 74 Snow Build-up . . . . . . . . . . . . . . . . . 18 Snow Conditions . . . . . . . . . . . . . . . 21 Spark Plugs. . . . . . . . . . . . . . . . . 92-93 Speed . . . . . . . . . . . . . . . . . . . . . . . . 15 Spring Preload, Front Suspension . . 51 Spring Preload, IQ . . . . . . . . . . . . . . 54 Steering Inspection . . . . . . . . . . . . . 113 Steering System . . . . . . . . 66, 113-115 Stop Switch. . . . . . . . . . . . . . . . . . . . 78 Stopping . . . . . . . . . . . . . . . . . . . . . . 81 Storage, Daily. . . . . . . . . . . . . . . . . . 82 Storage, Extended. . . . . . . . . . 116-117 Studs . . . . . . . . . . . . . . . . . . . . . . . . . 62 Survival Preparation . . . . . . . . . . . . . 11 Suspension Adjustments, Front . 50-52 Suspension Adjustments, IQ . . . 54-59 Suspension Adjustments, Rear . . 53-59 Suspension Coupling, IQ . . . . . . . . . 57 Suspension Inspection . . . . . . . . . . . 70 Suspension Lubrication, Front . . . . . 89 Suspension Lubrication, Rear. . . . . . 88 137

INDEX S

Suspension Performance Tips . . . . . 53 Suspension, Front . . . . . . . . . . . . . . 50 Switch, Stop. . . . . . . . . . . . . . . . . . . 78 Switch, Throttle Safety . . . . . . . 65, 78

T

Throttle Cable Lubrication . . . . . . . 89 Throttle Lever . . . . . . . . . . . . . . 65, 79 Throttle Safety Switch . . . . . . . . 65, 78 Torque Stop . . . . . . . . . . . . . . . . . . 107 Torsion Spring Preload, IQ . . . . . . . 55 Towing. . . . . . . . . . . . . . . . . . . . . . . 82 Track Alignment . . . . . . . . . . . . . . 112 Track Inspection . . . . . . . . . . . 69, 108 Track Lubrication . . . . . . . . . . . . . 109 Track Replacement . . . . . . . . . . . . 108

T

Track Tension . . . . . . . . . . 59, 110-111 Track Warm-Up . . . . . . . . . . . . . . . . 74 Track Warning . . . . . . . . . . . . . . . . . 25 Traction Products . . . . . . . . . . . . 62-63 Transporting the Snowmobile . . . . . 117 Troubleshooting Drive Belt Wear/Burn . . . . . . . 123 IQ Suspension . . . . . . . . . . . . . 122 Troubleshooting, Engine . . . . . 119-121

V

Vehicle Identification Numbers . . . . . 7

W

Warning Labels/Decals . . . . . . . . 24-27 Wear Strips . . . . . . . . . . . . . . . . . . . . 63 Weight Transfer . . . . . . . . . . . . . . . . 59 Windchill/Temperature Charts . . . . . 23 138

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