Polaris 2003 Universal Snowmobiles- Manuals

4 TABLE OF CONTENTS Section 1 - Introduction 5 - 9 . . . . . . . . . . . . . . . . . . This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner’s Manual. Section 2 - Safety 11 - 33 . . . . ...

5 SECTION 1 - INTRODUCTION Important Notes for Drivers 6 . . . . . . . . . . . . . . . . . Preservation Of The Environment 7 - 8 . . . . . . . . Vehicle Identification Numbers 9 . . . . . . . . . . . . . . Section 1 contains helpful information for owners and drivers and illustrates the location of ...

6 INTRODUCTION Important Notes For Owners And Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n This manual contains the latest information at the time of printing. We reserve the right to make product changes ...

7 INTRODUCTION Preservation Of The Environment Please 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 ...

8 INTRODUCTION Preservation Of The Environment Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

9 INTRODUCTION Vehicle Identification Numbers Please record your snowmobile identification numbers below for future reference: Tunnel VIN (lower right side of the tunnel) Engine Serial Number (right front side of engine crankcase) Remove the spare key and store it in a safe place. Your key can be du...

12 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your snowmobile or in this manual,...

13 SAFETY Operator Safety Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under...

14 SAFETY Operator Safety Stay Away From Moving Parts Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.We recommend having your dealer perform track service and alignment procedures. WARNING Be ale...

15 SAFETY Operator Safety Be Seated and in Position to Control the Vehicle Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. WARNING Operating a snowmobile re...

16 SAFETY Operator Safety Do Not Overload Cargo Carrier 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. Always Wear Clothing Designed for Snowmobiling...

17 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Know the Limitations of th...

18 SAFETY Operator Safety Know the Limitations of the Machine and Your Skills as a Driver 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 ther...

19 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Snow...

20 SAFETY Operator Safety Driving in Hilly Terrain Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.If you must cross the face of a slope, keep your weight on the uphill side of the ma...

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

22 SAFETY Operator Safety Do Not Operate Engine With Intake Silencer or Filter Removed Damage to the engine may occur if the intake silencer or filter are removed. Do Not Service Clutches Yourself All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at ...

23 SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20 _ F), Polaris recommends closing...

24 SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 106 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer ...

25 SAFETY Operator Safety Responsible Driving Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. E...

26 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.WIND CHILL CHART ( ° F) Estimated Wind Speed in MPH Actual Thermometer Reading ( ° F) in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Equiv...

28 SAFETY Safety Decals And Locations NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed...

29 SAFETY Safety Decals And Locations Track Warning Decal - 4 The track warning decal is on the rear of the tunnel (4): Stay clear of track.Do not sit on seat back or cargo area.Combined cargo and tongue weight should not exceed 40 lbs. (18 kg). Cargo load affects machine steering response. OR Stay ...

30 SAFETY Safety Decals And Locations Passenger Warning - 5 Some snowmobiles are designed for the operator only, while others are designed for the operator and one passenger. A warning decal on either the console or the hood of your machine indicates whether it’s designed for the operator only (1-Up...

31 SAFETY Safety Decals And Locations Standard Reverse Warning Decal - 6 Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal(s) above the instrument housing. The decals shown here are provided for identification and location purposes only. The text foun...

32 SAFETY Safety Decals And Locations Reverse Warning Decal - 7 Some Polaris snowmobiles are equipped with electronic reverse and will have this electronic reverse decal: Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, ...

33 SAFETY Safety Decals And Locations Operation Warning Decal Text: S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is missing, contact a Polaris dealer for a replacement. S This vehicle is capable of high speeds. Buried obj...

35 SECTION 3 - FEATURES AND CONTROLS Location of Controls 36 - 38 . . . . . . . . . . . . . . . . . . . Features 39 - 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 illustrates the locations of your snowmobile’s controls and features.

36 FEATURES AND CONTROLS Location of Controls NOTE: Your machine may not look exactly like the illustration, but these controls are found in the same general area on all machines. 1. Fuel Filler Cap (some models have a fuel gauge in the cap) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may incl...

37 FEATURES AND CONTROLS Location of Controls NOTE: Some Polaris snowmobiles are equipped with special features. Controls for these features are illus- trated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of features on your machine. Access...

38 FEATURES AND CONTROLS Location of Controls NOTE: Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features . Refer to your Owner’s Manual Supplement for a list of features on your machine. Accesso...

39 FEATURES AND CONTROLS Features 1. Hood 12. Suspension 2. Headlight 13. Nosepan 3. Windshield 14. Trailing Arm 4. Handlebar 15. Skis 5. Seat 16. Front Bumper 6. Storage/Rear 17. Console 7. Taillights 18. Rear Bumper 8. Backrest 19. Lifting Hand Hold 9. Tunnel Extension 20. Snow Flap 10. Passenger ...

40 FEATURES AND CONTROLS Features 1. Hood 12. Suspension 2. Headlight 13. Nosepan 3. Windshield 14. Trailing Arm 4. Handlebar 15. Skis 5. Seat 16. Front Bumper 6. Storage/Rear 17. Console 7. Taillights 18. Rear Bumper 8. Backrest 19. Passenger Hand Hold 9. Tunnel Extension 20. Lifting Hand Hold 10. ...

43 SECTION 4 - THE PERFECT FIT Front Suspension Adjustments 44 - 48 . . . . . . . . . Rear Suspension Adjustments 49 - 58 . . . . . . . . . M-10 Suspension 59 - 68 . . . . . . . . . . . . . . . . . . . . . . Handlebar Adjustment 69 . . . . . . . . . . . . . . . . . . . . . Backrest Adjustment 70 . ....

44 THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before fine-tuning adjustments are made.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions...

45 THE PERFECT FIT Front Suspension Adjustments The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. To determine if your machine is...

46 THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the left and right sides of the machine are at ...

47 THE PERFECT FIT Front Suspension Adjustments If the spring preload is at its maximum and you want more adjustment: D Remove the existing spring and install the next highest rate spring, or D Change the shock valving on Fox t , RYDE FX t , and Walker/ Evans t shocks, or D Increase compression damp...

48 THE PERFECT FIT Front Suspension Adjustments Indy Select IFS Shock Some snowmobiles are equipped with Indy Select IFS shocks, which allow you to make adjustments to the compression valving of the front shocks by turning adjustment screws (A) located near the base of the shocks.By turning the scre...

49 THE PERFECT FIT Rear Suspension Adjustments Rear Suspensions Polaris has a suspension to meet your needs. Each is designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear susp...

50 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting EDGE RMK (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.Take this measurement with no rider and wi...

51 THE PERFECT FIT Rear Suspension Adjustments Rear Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool.Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information.The following in...

52 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting Xtra-10, EDGE and Xtra Lite (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.Take the first measurement ...

54 THE PERFECT FIT Rear Suspension Adjustments Indy Select Front Track Shock Some snowmobiles are equipped with the Indy Select front track shock, which allows the driver to make adjustments to the compression valving by turning the screw located near the base of the shock. Adjustment Locate the adj...

55 THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Adjustment Locate the adjustment screw (A) ...

56 THE PERFECT FIT Rear Suspension Adjustments Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information. Position Sensitive Shock (PPS) There are no external adjustments on the position sensitive shock. Ther...

57 THE PERFECT FIT 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 independent movement between the rear torque and the front torq...

58 THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration Xtra-10 and EDGE Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the rear rear scissor stop (RRSS). The RRSS is locate...

59 THE PERFECT FIT M-10 Suspension Before proceeding with the tuning of your M-10 suspension, you should familiarize yourself with the following terms: Description of M-10 Features Long Travel - Refers to the over 10 ″ of REAL travel that the M-10 has between the rear arm cross-shaft and the slide r...

60 THE PERFECT FIT M-10 Suspension NOTE: The M-10 has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. or more might require ap- propriate changes in FRA settings. Refer to the chart on page 64 for specifications. Internal Floating Piston Shock - A high-pressure...

61 THE PERFECT FIT M-10 Suspension Optional Spring Rates - Optional springs have been designed to allow adaptation of the M-10 to the varied needs of our customers. The 140 lb/in option front arm spring would be used when very light loads are encountered such as very smooth trails, deep powder or by...

62 THE PERFECT FIT M-10 Suspension SAG SETTINGS - Describes the difference in height of the rear bumper from the sleds fully extended position to its loaded height with the rider seated on the sled.A good initial starting point is 4 ″ of SAG. Note that this measurement is at the rear bumper. Too muc...

63 THE PERFECT FIT M-10 Suspension Rear Suspension Setup 1. Adjusting the Full Range Adjuster (F.R.A.) 1. Refer to the initial set-up reference chart (located under the hood of your snowmobile and on page 64) to determine the desired F.R.A. position. 2. To adjust, loosen the hex bolts (A) attaching ...

64 THE PERFECT FIT M-10 Suspension INITIAL SET-UP REFERENCE CHART This chart is a guideline to be used for initial suspension setups. Your setup may vary based on your desired riding style. FRA Location A Dimension B Dimension C Rider Weight with SOFT FRA FIRM FRA Rear Spring X-over Tube Limiter/Ski...

65 THE PERFECT FIT M-10 Suspension Setting the Rear Compression Spring Preload Dimension B 1. Using the spanner wrenches in your tool kit, rotate the x--over tube assembly to achieve the desired spring preload setting. Be certain the aluminum locknut and adjuster collar are locked against each other...

66 THE PERFECT FIT M-10 Suspension SETTING LIMITER / SKI PRESSURE Your M-10 rear suspension has come from the factory set up to delivery 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...

67 THE PERFECT FIT M-10 Suspension SAG / RIDE HEIGHT SETTINGS 1. To check if the FRA settings are close before riding, check the SAG settings. Raise the rear bumper until the suspension is fully extended (rear shock will not extend any further) and measure the distance from the ground to the bottom ...

68 THE PERFECT FIT M-10 Suspension TRACK TENSION Track adjustment is critical for proper handling. Always maintain correct tension and alignment.Tension adjustments should be made only after the track is warmed up and limber.1. Turn the machine off.2. Lift the rear of the machine and safely support ...

69 THE PERFECT FIT Standard Handlebar Adjustment Follow these steps to adjust the handlebars for a personal fit.1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts (A). 2. Using a 7/16 ″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (tur...

70 THE PERFECT FIT Backrest Adjustment The passenger backrest on some models is adjustable.To move the backrest forward or backward, lift the adjustment lever on the left side (1).When adjusting the backrest from a passenger position to a single rider position, rotate the backrest cushion adjustment...

71 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. NOTE: The accessory tether switch is available for all...

72 THE PERFECT FIT Accessories Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Polaris...

73 THE PERFECT FIT Accessories Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. Aggressive studding patterns may require grinding protruding st...

74 THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information.Some models are manufactured with tunnel wear strips or wear strip coolers installe...

75 SECTION 5 - GETTING READY TO RIDE Check Before Starting Engine 76 - 80 . . . . . . . . . . D Throttle Freeplay D Brake D Fluid Levels D Steering D Mirrors D Gear Start the Engine and Check 81 . . . . . . . . . . . . . . . . D Lights D Stop Switch D Skis and Track (cold/warm) D Pre-ride warm-up Ce...

76 GETTING READY TO RIDE Check Before Starting Engine Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling. Check Throttle and Brake for Pro...

77 GETTING READY TO RIDE Check Before Starting Engine Hydraulic Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel When the brake lever is squeezed, it should move no closer to the...

78 GETTING READY TO RIDE Check Before Starting Engine Mechanical Brakes Brake Lever Travel Firmly depress the brake lever. Measure the distance (A) between the lever and brake block. The distance should be no more than 3/4 ″ (1.9 cm). If the distance is greater than this recommendation, the brake ca...

79 GETTING READY TO RIDE Check Before Starting Engine Park Brake Lever Lock Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes...

80 GETTING READY TO RIDE Check Before Starting Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable ...

81 GETTING READY TO RIDE Start the Engine and Check n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine. n Tether Switc...

83 SECTION 6 - OPERATION Starting Your Engine 84 - 85 . . . . . . . . . . . . . . . . . . Engine Break-In 86 - 87 . . . . . . . . . . . . . . . . . . . . . . . Track Warm-Up 88 - 89 . . . . . . . . . . . . . . . . . . . . . . . Fuel 90 - 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

84 OPERATION Starting Your Engine Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts.1. Turn key to “ON.”2. Pull kill switch (shut-off switch) up to “RUN.”3. Flip choke toggle to “FULL ON.” 4. Grasp starter handle and pull slowly until recoil engages; then pull...

85 OPERATION Starting Your Engine Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts.1. Flip choke toggle to “FULL ON.” 2. Pull kill switch (shut-off switch) up to “RUN.” 3. Turn key to “START” and crank engine. 4. After the engine starts, release the key to ...

86 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication su...

87 OPERATION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are controlled by the oil pump and correspond to the engine’s RPM and throttle valve opening. Variable Exhaust System All snowmobile engines equipped with variable exhaust valves sh...

89 OPERATION Track Warm-Up 5. The engine, drive system and track are now properly warmed up and the machine may be driven following normal safety practices. Always inspect for track damage before operating the snowmobile. Use of traction products such as studs, ice growsers, etc. will increase the p...

90 OPERATION Fuel Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill...

91 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used.Most Polaris engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane ...

92 OPERATION Fuel Premium Fuel Switch If you’re uncertain about the quality or octane rating of the fuel you use, turn your key switch to “ON/REG.” The “Premium fuel” light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not reco...

93 OPERATION Oil Low Oil Indicator Light The low oil indicator light (standard on most models) will indicate when to add oil. However, always check the oil level when refueling. When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the...

94 OPERATION Oil Low Oil Level Always do a visual check of the oil level when refueling. In the illustration, * indicates a low oil level. When the oil reaches the low level mark, add one U.S. quart of oil to the tank.Always use a Polaris oil cap, never substitute. Your Polaris oil cap may be vented...

95 OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.A lea...

96 OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to “ON.” Throttle Safety Switch Test the throttle safety switch syst...

97 OPERATION Throttle Lever If the engine stops abruptly when the throttle lever is released:1. Turn the ignition switch to “OFF.” 2. Visually inspect the throttle cable and carburetor(s) to determine what caused the safety switch to activate. 3. Test the throttle lever by compressing and releasing ...

98 OPERATION Emergency Stopping And Starting Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 96 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Inte...

99 OPERATION Emergency Stopping And Starting Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machine’s equipped with electric start have a recoil for emergency starting. On non-electric start models, if the recoil starter system fails, an emergency sta...

100 OPERATION Reverse Operation (Mechanical) Make sure the shift lever is shifted completely into forward or reverse position. Some models are equipped with a reverse indicator light that will help you make that determination.Do not force the shift lever into reverse if resistance is felt. The gears...

102 OPERATION Reverse Operation (Electronic) Forward When running in reverse, again push the yellow reverse button on the left-hand control for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off. Make sure the area around you...

103 OPERATION Towing For your safety, the proper function of a tow hitch must be understood before attempting its use. If the snowmobile is 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 the ski loops) to prevent damage to ...

105 SECTION 7 - MAINTENANCE Polaris Recommended Maintenance Program 106 . . . . . . . . . . . . . . . . . . . . Maintenance Charts 107 - 108 . . . . . . . . . . . . . . . . . Maintenance Log 109 - 110 . . . . . . . . . . . . . . . . . . . . Lubrication 111 - 120 . . . . . . . . . . . . . . . . . . ....

106 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual.The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections...

107 MAINTENANCE Maintenance Chart 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 Weekl...

109 MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized ...

110 MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service

111 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium grease (PN 2871066) annually or about every 1000 miles (1600 km). The illustration shows the location of suspension and steering components. The + in the illustration indicates a grease point or fitting...

117 MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two p...

118 MAINTENANCE Lubrication Throttle Cable Lubrication Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubrication Lubricate the choke slide (2) and cables lightly with oil or grease. Befo...

119 MAINTENANCE Lubrication Chaincase Oil Level It’s the operator’s responsibility to check and maintain the proper chaincase oil level.To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris chaincase oil (PN 28...

120 MAINTENANCE Lubrication Gearcase Oil Level (WideTrak Models) It’s the operator’s responsibility to maintain proper gearcase oil level.To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). See your Polaris dealer for th...

121 MAINTENANCE General Maintenance Intake Filter 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. NOTE: These illustrations are general representations. Your mo...

122 MAINTENANCE General Maintenance Under Hood Air Intake System The under-hood air intake system on Indy 340 Tourings should normally be left open. However, for maximum performance in temperatures above 35 ° F (2 ° C) and in loose snow, the door should be closed and latched (A). Pull the strap out ...

124 MAINTENANCE General Maintenance Spark Plug Removal and Replacement Remove the spark plug with the special wrench (1) provided in the tool kit.1. Remove the spark plug cap. 2. Rotate the plug counterclockwise and remove it. 3. Install the new spark plug, rotating clockwise. 4. Torque to 18-22 ft....

125 MAINTENANCE General Maintenance Variable Exhaust System (V.E.S.) Maintenance of the V.E.S. is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles, bring the machine to an authorized Polaris dealer to have the V.E.S. disassembled, inspected, and cleaned. N...

126 MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 2000 miles (3200 km) and inspected for...

127 MAINTENANCE General Maintenance Fuel Filter/Fuel Lines Oil Filter The oil filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 2000 miles (3200 km). Polaris oil filters are specially designed for use on Polaris products. Use only Polaris replacement part...

128 MAINTENANCE General Maintenance General Carburetor Information The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is ...

129 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing re...

130 MAINTENANCE General Maintenance Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34 ° F (-37 ° C). If greater protection is required, the percentage of antifreeze to...

131 MAINTENANCE General Maintenance Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be d...

132 MAINTENANCE General Maintenance Surge Tank Models 1. Remove the pressure cap and fill the recovery tank with properly mixed coolant to the maximum indicated mark. 2. Elevate the front end of the machine slightly to aid in bleeding of the heat exchangers. 3. Remove the bleed screw from the water ...

133 MAINTENANCE General Maintenance EDGE RMKs 1. Remove pressure cap and fill tank to maximum recommended mark. 2. Elevate the front of the machine.3. Start the engine and run at a fast idle for two to three minutes. Air bubbles should come to the surface of the coolant tank. Run the machine until a...

134 MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2 ″ (1.3 cm). Brake pads m...

135 MAINTENANCE General Maintenance Brake Components 1. Brake Caliper 2. Chaincase 3. Brake Disc 4. Backing Plate 5. Brake Pad Material (Replace when thickness is less than 1/16 ″ ). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as describ...

136 MAINTENANCE General Maintenance Replenishing Brake Fluid Frequently check the reservoir to be sure it contains the correct amount of fluid.Remove the brake master cylinder reservoir cover. Add Polaris brake fluid (PN 2870990) as required to bring the level up to the top of the fluid level mark o...

137 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system. 1. Remove brake master cylinder reservoir cover and gasket.2. Fill the master cylinder res...

138 MAINTENANCE General Maintenance Mechanical Brake Lever Travel Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and the brake block. This distance, brake lever reserve (A), should be no more than 3/4 ″ (1.9 cm). If brake lever ...

139 MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure:1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the he...

140 MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the ...

141 MAINTENANCE General Maintenance Removing the Side Bulbs 1. Disconnect terminal from back of bulb. 2. Turn bulb assembly 1/4 turn to right and withdraw from housing. Installing the Side Bulbs 1. Hold bulb assembly by plastic base and plug into wire terminal. 2. Insert bulb assembly into housing. ...

142 MAINTENANCE General Maintenance Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. Standard Belt R...

143 MAINTENANCE General Maintenance Standard Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can r...

144 MAINTENANCE General Maintenance Clutch System Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil based cleaners such as isopropyl alcohol. All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, s...

145 MAINTENANCE General Maintenance Clutch Alignment and Offset Clutch center distance and alignment (A) are crucial to maintaining optimum performance. See your Owner’s Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed.The drive belt is a very ...

146 MAINTENANCE General Maintenance Clutch Center Distance See your Owner’s Manual Specification Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer. Due to tolerances in belt length, it may be necessary for your dealer to make minor adjustments i...

147 MAINTENANCE General Maintenance Accessory Reverse Kit If you’ve had a reverse kit installed on your snowmobile, some maintenance will be required. Follow these recommendations: Chain Tension Maintain the proper chain tension as outlined on page 133. Oil Level Maintain the oil level between the s...

148 MAINTENANCE General Maintenance Tool Kit A tool kit is included with your machine for emergency and routine maintenance. The tool kit received with your sled will not have all the tools that are listed. The following tools are available:A. Emergency Start Strap (on electric start models)B. Phill...

149 MAINTENANCE General Maintenance For Your Protection For added protection, carry the following items on your snowmobile at all times: S Spare Drive Belt S Extra Set of Spark Plugs S Tow Rope S Extra Oil S Fuel Deicer S Winter Survival Kit S Trail Map S Owner’s Manual S First Aid Kit Fall Tune-Up ...

150 MAINTENANCE Track Maintenance Track Tension Data Suspension (See Owner’s Manual Supplement for type) Weight Measurement Location Measurement XTRA 12 121 ″ 10 lbs. (4.54 kg) 2 ″ behind rail bumper 3/4 ″ (1.9 cm) XTRA 12 133 ″ 10 lbs. (4.54 kg) 16 ″ ahead of rear idler shaft 3/4 ″ (1.9 cm) XTRA 10...

151 MAINTENANCE Track Maintenance Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment.Tension adjustments should be made only after the track is warmed up and limber.1. Turn the machine off.2. Lift the rear of the machine and safely support i...

152 MAINTENANCE Track Maintenance I f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brak...

153 MAINTENANCE Track Maintenance Track Inspection Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for possible damage.Carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. T...

154 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the following illustrations. + CRC Suspension With Rack Steering All Steering Except CRC Edg...

155 MAINTENANCE Steering System Ski Alignment With handlebars in 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 ″ greate...

157 MAINTENANCE Steering System Ski Skags Check skags weekly to maintain positive steering characteristics. Skags must be replaced when worn to half their original diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Identification A. Steel ski 1. Standard s...

158 MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring thickness at several points along the rail. Replace Hi-fax when a thickness of 5/16 ″ (.8 cm) is reached (7/16 ″ on Xtra Lite models). Take the machine to your dealer for Hi-fax replacement. NOTE: Hi-fax wear patterns ...

159 MAINTENANCE Suspension Maintenance Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long tri...

160 MAINTENANCE Extended Storage Bearings Grease jackshaft and drive shaft clutch side bearings with a high quality bearing grease to prevent corrosion. Clutch and Drive System Remove drive belt and store in cool dry location. Lubricate sheave faces of drive and driven clutches with a light coat of ...

161 MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure:1. Transfer unused fuel from the fuel tank to an approved fuel conta...

162 MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported:1. Turn the ...

163 MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper (1) and lower (2) level marks. Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact w...

164 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water an...

165 MAINTENANCE Battery When your snowmobile is placed in storage for one month or more: D Remove the battery. D Charge it to the proper level. D Store it in a cool dry place. D Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging.Batteries may fre...

167 SECTION 8 - TROUBLESHOOTING Suspension Troubleshooting 168 - 171 . . . . . . . . . Belt Troubleshooting 172 . . . . . . . . . . . . . . . . . . . . . Engine Troubleshooting 173 - 175 . . . . . . . . . . . . . Section 8 is a quick reference guide to solving problems.

168 TROUBLESHOOTING Suspension Troubleshooting X-12, 133 ″ Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily -Check to be sure FRSS block is in highest position-Adjust torsion spring blocks to highest position-Adjust coil over spring on front track shock to incre...

170 TROUBLESHOOTING Suspension Troubleshooting EDGE RMK Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily -Adjust torsion spring blocks -Increase torsion spring diameter (see your dealer) -Increase rear shock compression damping by turning screw clockwise (RMK) o...

171 TROUBLESHOOTING Suspension Troubleshooting XTRA LITE Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily -Adjust torsion spring block to next higher position-Increase rear shock compression damping by turning screwclockwise-Change torsion springs to next higher...

172 TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check beltdeflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt offthe machine in extremely cold wea...

173 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engineoperating RPMduring accelera-tion or loadvariations Drive clutch bind-ing Driven clutchma...

177 SECTION 9 - WARRANTY Service and Warranty Information 178 . . . . . . . . . Warranty 179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Year Engine Service Contract 182 . . . . . Section 9 contains specific warranty information.

178 WARRANTY Service And Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

179 WARRANTY Limited Warranty Polaris Industries 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 defecti...

180 WARRANTY Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship. The warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. The warranty also does not cove...

181 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states d...

182 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused model year 2003 Polaris snowmobiles that were Snow Checked between 3/8/02 and 4/15/02. The free Second Year Engine Service Contract is honored by all authorized Pol...

183 WARRANTY Polaris Second Year Engine Service Contract Coverage S Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized part...

184 INDEX Accessories 71-76 . . . . . . . . . . . . . . . . . . Adjustment, Backrest 70 . . . . . . . . . . . . . Adjustment, Front Suspension 44-50 . . . Adjustment, Handlebar 69 . . . . . . . . . . . . Adjustment, Headlight 139 . . . . . . . . . . . Adjustment, Indy Select Front Track Shock 54 . ....