Polaris 7427 C - Manuals

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...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lo...

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 manu...

9 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 99 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. ...

10 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the igni- tion, raise the hood, make the adjustment, secure shields an...

11 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 prop...

12 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 established safety standards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.Ap...

13 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 mode...

14 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. 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...

15 SAFETY Operator Safety Excessive Speed 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...

16 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 wi...

17 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...

18 SAFETY Operator Safety I ce and Snow Build-up Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. NOTE: ...

19 SAFETY Operator Safety Driving on Slippery Surfaces 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 main...

20 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operat...

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. Driving in too little snow will result in excessiv...

22 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....

23 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART ( ° F) WIND CHILL CHART ( ° C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 ...

24 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...

25 SAFETY Safety Decals and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the left console: WARNINGThis vehicle is designed for operator only.“NO PASSENGER” Passenger Warning Snowmobiles designed for an operator and one passenger have a warning...

26 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console: WARNINGReverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look beh...

27 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, con- tact a Polaris dea...

28 FEATURES 1. Nosepan2. Skis3. Front Bumper (do not use for pulling or dragging the snowmobile) 4. Hood5. Headlight6. Windshield7. Storage Compartment or Cargo Bag 8. Operator Seat9. Passenger Seat10. Backrest11. Passenger Grab Handle12. Grab Handle Heater Switch13. Taillights14. Rear Bumper15. Sno...

29 FEATURES 1. MFD Display2. Mirrors3. Rider Select t 4. Fuel Filler Cap5. Handlebar6. Hood Hold Down Straps 7. Handlebar Grip Warmer Switch 8. Thumbwarmer Switch9. Electronic Reverse Button 10. MFD Control11. Headlight Dimmer Switch 12. Parking Brake Lock13. Brake Lever14. Engine Stop Switch15. Thr...

30 FEATURES Backrest The backrest is adjustable for either operator or passenger use. See page 32 for passenger seat installation instructions.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 ...

31 FEATURES 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. Cargo Bag (Touring) The cargo bag is secured t...

33 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 be...

34 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...

35 FEATURES RIDER SELECT Adjustable Steering System Choosing the Best RIDER SELECT Position Position Riding Style 123 Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding. 45 General Trail Riding, Boondocking, Deep Snow Riding Rider wei...

36 FEATURES RIDER SELECT Adjustable Steering System 1. Stop the snowmobile.2. Press the release button and move the handlebar forward or rearward to the desired position. WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious in...

37 FEATURES Engine Management System Malfunction Indicator Lamp (MIL) Illuminated MIL The MIL (Check Engine Indicator) will illuminate when a problem with engine management system components is detected.1. Turn the engine off and restart it. If the light goes off, continued operation is permissible....

38 FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (if equipped) if the following condi- tions are encountered. Under extreme overheating conditions, the sys- tem will also stop the engine entirely to prevent e...

39 FEATURES Engine Management System The engine management system is programmed to alert the rider when coolant temperatures reach higher-than-normal levels. The system responds by taking the following sequential steps to alert the rider. 1. The High Temperature Indicator on the MFD will flash. To c...

40 FEATURES Knock Sensor (Turbo Models) A knock sensor monitors the engine and responds to detonation by auto- matically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. NOTE: Engine performance will be reduced if fuel with a lower octane than 91 is u...

41 FEATURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electri...

42 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.MFD settings can be made with the engine running o...

43 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 analo...

44 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 cyc...

46 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 t...

47 FEATURES Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temp...

48 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. NOTE: Press and hold the MODE switch for...

49 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped).Press and release the SET button to cycle through the Ma...

50 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 serv...

51 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,...

52 FEATURES Instrumentation MFD Digital Display Programs M-10 ACE Suspension Adjustments (Cruiser) A switch on the console (above the ignition switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. See page 69 for instructions. MFD Battery Replacement Models equipped with ...

53 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. NOTE: The battery will not come out of the holder unless the leading edge of the ...

54 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 condi...

55 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempt- ing to adjust preload.Increasing the spring preload too much may adversely aff...

56 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. Front Springs The front spring rates can be adjusted by changing the nitrogen pressure. The upper ch...

57 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...

58 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 ...

59 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 ...

60 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 sus- pension coupling, these torque arms could move independently of each other. Rear suspens...

61 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...

62 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions.To decrease weight transf...

63 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning y...

64 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as s...

65 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA:1. Refer to the initial set-up reference chart (see ...

66 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and c...

67 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to th...

68 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole increases ski pressure while the upper hole decreases ski pressure. NOTE: By design,...

69 THE PERFECT FIT FAST M-10 ACE Rear Suspension Adjustments MFD Suspension Adjustments (Cruiser) A switch on the console (above the ignition switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. NOTE: The engine must be running to make suspension adjust- ments with the M...

70 THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 34. 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" wren...

71 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in:• Non-compliance with government/industry requi...

72 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 warran- ties are void if track damage or failure results from ...

73 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...

74 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 See P...

75 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. Read and Understand Your Owner's Manual Read the Owner...

76 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...

77 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 leve...

78 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 Lever2. Parking Brake Lever Lock3. Master Cylind...

79 PRE-RIDE INSPECTIONS Before Starting the Engine n Track Inspection NOTE: Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty. WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause ...

80 PRE-RIDE INSPECTIONS Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on...

81 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n Lightin...

83 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 fi...

84 OPERATION Break-In Period The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as impor- tant as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more...

85 OPERATION Starting the Engine 1. Turn the key to the ON position.2. Pull the engine stop switch up to the RUN position.3. Do not apply throttle when starting the engine unless extremely cold temperatures (below -15 ° F/-26 ° C) prevent the engine from start- ing. NOTE: Under these conditions, att...

86 OPERATION Emergency Starting If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions on the following pages. NOTE: If a car or truck...

87 OPERATION Emergency Starting 1. Always wear eye protection when jump starting your vehicle. 2. Keep bystanders away from the vehicles.3. Perform the emergency starting procedure in a well-ventilated area.4. Position the vehicles close enough for the jumper cables to reach easily between the batte...

88 OPERATION Emergency Starting 12. Make sure that the engine stop switch is in the UP position. 13. Attempt to start the vehicle. 14. If the engine does not turn over (crank over), wait 30 to 60 seconds and attempt to start the engine again. If the engine does not start, wait another 1 to 2 minutes...

89 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 ...

92 OPERATION n Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to limit engine speed to 2400 RPM whenever all pre...

94 OPERATION Electronic Reverse (PERC 4 t ) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum vehicle speed when oper- ating in reverse will be approximately 12 MPH (19 km/h). Engaging Reverse 1. Stop the snowmobile and leave the engine idl...

95 OPERATION Electronic Reverse (PERC 4 t ) 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...

96 OPERATION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) off the ground.Remove the key and cover the snowmobile. Towing Do not use the front bump...

97 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) l...

98 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 166, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is per- formed, including the emissi...

99 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 168.The recomm...

100 MAINTENANCE Periodic Maintenance Interval Table O = Perform ServiceX = Replace DAIL Y or PR E-R ID E INITIALLY Miles (km) YE A R LY or E VER Y M ile s ( km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Stop Switch 81 Test for proper operation. Do not operate...

103 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Table beginning on page 100. Always change the oil filter whenever changing oil. See page 151 for the part numbers of Polaris products. Performance Synthetic 4-Stroke (PS-4) Oil Po...

104 MAINTENANCE Engine Oil n Oil Level Check NOTE: Read the entire oil check procedure before checking the oil level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. To obtain a proper oil level reading, the snowmobile must be on a level ...

105 MAINTENANCE Engine Oil n Oil Level Check NOTE: The oil level in the oil bottle may drain below the level of the dipstick if the engine has not run for more than a week. If you're not sure if there is oil in the system, you must first check to make sure oil is in the sys- tem before checking the ...

107 MAINTENANCE Engine Oil Oil in System Check 1. Position the vehicle on a level surface. Start the engine and allow it to idle 3-5 seconds (no more than 5 seconds). Turn the engine off. 2. Remove the dipstick. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. ...

108 MAINTENANCE Engine Oil Oil Change Always change the oil at the intervals outlined in the Periodic Mainte- nance Table beginning on page 100. Clean the foam oil breather element with each engine oil change. See page 112.Always use the recommended oil. See page 104, or see your Polaris dealer abou...

111 MAINTENANCE Engine Oil Oil Change 26. Add additional oil to bring the level slightly above the lower mark (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. NOTE: Check the oil level often during the fill procedure to avoid ...

112 MAINTENANCE n Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to pro- tect sensors within the intake system from damage due to oil ingestion. Check the element before each ride. Clean or replace the breather ele- ment at each engine oil change. Clean the e...

113 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speed- ometer 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 ligh...

114 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 100 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 mi...

115 MAINTENANCE Gearcase Oil n Gearcase Oil Check Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 100.Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 151 for the part numbers of Polaris products.The dipstick is ...

116 MAINTENANCE Gearcase Oil Gearcase Oil Change The drain plug is located on the bottom of the gearcase. NOTE: Polaris does not recommend tip- ping the snowmobile onto it's side for service. Any time the snowmo- bile is tipped onto it's left side, always check the oil level and clean the foam oil b...

117 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. • Use recommended spark plugs with the proper gap.• Use only resistor-type spark plugs...

118 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. NOTE: The tip should not be white. A whi...

120 MAINTENANCE n Alternator Belt Inspection Inspect the alternator belt condition and tension before each ride.1. Stop the engine.2. Open the hood.3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, install a new belt. 4. Grasp the alternator belt and attempt to tw...

121 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 100. 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 we...

122 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required.Use Premium 60/40 anti-freeze coolant, which is already premix...

123 MAINTENANCE Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are:• Coolant bottle or overflow tank• Filler neck• Pressure cap• Connecting hosesAlways maintain the coolant level at the “COLD FILL” mark on the cool- ant ta...

124 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. Stop the snowmobile and allow the engine to cool. Place snow on the coolers to he...

125 MAINTENANCE Cooling System 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 mix- ture of antifreeze and distilled water should be added. Have your Polaris dealer perform this se...

126 MAINTENANCE Cooling System Bleeding the Cooling System 3. Open the hood.4. Remove the coolant pressure cap carefully. 5. Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck. Leave the pressure cap off. 6. With the cap of...

128 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. ...

129 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 77.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 br...

130 MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 151 for the part numbers of Polaris products.The brake fluid level can be seen through the fluid level indicator (a plastic sight glass) in the master cyl- in...

131 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. During the bleeding procedure, keep the brake handle as level as possi- ble. The reservoir must be in this position to ...

132 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum cov- ering from...

133 MAINTENANCE Electrical System RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOID RELAY Ground side of start solenoid CHASSIS RELAY SPARE 20A None ACCESSORY EMERGENCY SPARE 30A Accessory plugs CHASSIS 30A High beamsLow beamsHandwarmersThumbwarmerTail lampBrake lampAlternator coils EFI RELAY EX. S...

134 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. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor- mance.Please ...

135 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. ...

136 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility, make sure the clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave. 2. Turn the ignition key off. Wait for the engine to co...

137 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If ...

138 MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. Track Inspection 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 f...

139 MAINTENANCE Track Lubrication The slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear. NOTE: Track damage or failure caused by op...

140 MAINTENANCE Track Tension Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment. NOTE: 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 snowmo- bile and safely support it of...

141 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.7. Tighten or loosen the track adjusting screws as necessary to provide equal ad...

142 MAINTENANCE n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small ...

143 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners. + + + + +

144 MAINTENANCE Steering System Ski Alignment 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...

145 MAINTENANCE Steering System n Ski Skags 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. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacemen...

146 MAINTENANCE Battery Battery Removal 1. Remove the left side panel.2. Disconnect the battery hold-down strap.3. Disconnect the black (negative) battery cable first.4. Disconnect the red (positive) battery cable last.5. Lift the battery out of the vehicle. Battery Installation When installing a ne...

147 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

148 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less un...

149 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 151 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts wit...

150 MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model. 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 par...

151 POLARIS PRODUCTS Part No. Description Engine Lubricants 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.) Chai...

152 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Engine Doesn't Turn Over Probable Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 38. Jammed clutch Check for twisted belt or broken spring. See your dealer. Ja...

153 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Engine Backfires Probable Cause Solution Out of fuel Refuel. Water is present in fuel See your dealer. Old or non-recommended fuel Replace with fresh recommended fuel. Fouled or defective spark plugs Inspect...

154 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Probable Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 38. Low battery voltage Recharge the battery to 12.8 VDC. Water is present in fuel See your dea...

155 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Overheating Harsh Drive Clutch Engagement Drive Belt Turns Over Drive System Noise Probable Cause Solution Inadequate snow conditions Stop and cool the engine. Drive into snow frequently to prevent overheating. See page 21. Low coolan...

156 TROUBLESHOOTING IQ Comfort Suspension Troubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 58). • Change torsion spring to stiffer optional spring (see your dealer). • Rotate RRSS to higher position (see page...

157 TROUBLESHOOTING M-10 Suspension Troubleshooting Problem Solution (Perform only one change at a time) Rear suspension bottoms too easily • Increase FRA position (see page 65).• Install appropriate optional center retainer on rear track shock (see page 66). • Increase front track shock coil spring...

158 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- up Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose...

159 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warranty. Your dealer receives frequent update...

160 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...

161 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED 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 ...

163 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the con...

164 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract ...

165 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 ex...

166 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine m...

168 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 k...

171 INDEX A Access Panel, Radiator Compartment 31 Accessories . . . . . . . . . . . . . . . . . . . . 71 Adjustable Steering System . . . . 34-36 Air Filter (Turbo)). . . . . . . . . . . . . . 120 Alternator Belt Inspection. . . . . . . . 120 Apparel . . . . . . . . . . . . . . . . . . . . . . . 12 ...

172 INDEX I Ice and Snow Build-up . . . . . . . . . . 18 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Instrumentation . . . . . . . . . . . . . . 41-53 Intake Filters . . . . . . . . . . . . . . . . . 119 Intake Silencer . . . . . . . . . . . . . . . . . 20 J-K Jump-Starting. . . . . ....

173 INDEX S Suspension Performance Tips. . . . . . 57 Suspension Set-up Chart, M-10 . . . . 68 Suspension, Front . . . . . . . . . . . . . . . 54 Switch Stop Switch . . . . . . . . . . . . . . . . 92 Suspension Adjustment Switch 30 Throttle Safety Switch . . . . . . . 92 T Throttle Cable Lubrication...