Polaris 800 Pro X - Manuals

5 TABLE OF CONTENTS Introduction 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety 10 . . . . . . . . ...

7 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 The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the ...

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 The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these ...

10 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manua...

11 SAFETY Operator Safety WARNING 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 ...

12 SAFETY Operator Safety Stay Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become ent...

13 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably...

14 SAFETY Operator Safety Excessive Speed Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machi...

15 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

16 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...

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

18 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...

19 SAFETY Operator Safety Driving on Slippery Surfaces Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions.It’s dangerous to drive on ice or ...

20 SAFETY Operator Safety Maneuverability Control and maneuverability comes not only through the steering and skis, maximum control is achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to carry a load or a passenger. Maintenance Your Polaris ...

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

22 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) Speed in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60...

23 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the ...

24 SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: Passenger Warning Polaris PRO X snowmobiles are designed for one operator only. A “No Passenger” warning decal is located on the console: + +

25 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal on the lower dash. + WARNING AVERTISSEMENT

26 SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English. WARNING

28 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on the following pages. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of specific features on your machine. Accessories are ...

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

33 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...

34 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 ...

35 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX and Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. Front Springs For models without externally adjustable or revalvable shocks, the fr...

36 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs a...

37 THE PERFECT FIT PRO X Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the PRO X 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 suspe...

38 THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Torsion 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.T...

39 THE PERFECT FIT PRO X Rear Suspension Adjustments Clicker Shock The position sensitive clicker shock is available as an option on some models. Adjustments to the compression damping are made by turning the clicker knob (A) on the shock reservoir.Position #1 is the softest, or least compression da...

40 THE PERFECT FIT PRO X 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. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that c...

41 THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.Adjusting the RRSS...

42 THE PERFECT FIT PRO X Rear Suspension Adjustments Weight Transfer During Acceleration PRO X Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the PRO X rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your t...

43 THE PERFECT FIT Handlebar Adjustments Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/2” wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required....

44 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. NOTE: The accessory tether switch is available for all models. Order PN 2870668.Use only Polaris parts and accessor...

45 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: Before ...

46 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...

47 THE PERFECT FIT Accessories Wear Strips Polaris PRO X models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See you...

48 PRE-RIDE INSPECTIONS Before Starting the 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 Proper...

49 PRE-RIDE INSPECTIONS Before Starting the 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 ha...

50 PRE-RIDE INSPECTIONS Before Starting the 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 or...

51 PRE-RIDE INSPECTIONS Before Starting the 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 com...

52 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine. n Tether Switch: If your machine has a tether switch, make sure the engine shuts off w...

53 OPERATION Starting the Engine Starting a Cold Engine 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 abruptly to star...

54 OPERATION Starting the Engine Starting a Warm Engine 1. Turn key to ON . 2. Pull kill switch (shut-off switch) up to RUN . 3. Grasp starter handle and pull slowly until recoil engages; then pull to start. If the engine does not start on the first pull, slightly depress the throttle with your left...

55 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 We recommend the use of Polaris VES two-cycle oil in all snowmo...

57 OPERATION Fuel Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area w...

58 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris snowmobile engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline, but a higher octane fuel (premium 91 octane) is preferre...

59 OPERATION Fuel Fuel Reserve Capacity There are approximately two gallons of fuel left in the tank when the fuel gauge indicates reserve ( RES). Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per g...

60 OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 55 for oil recommendations.When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may b...

61 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...

62 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 the ON position. Throttle Safety Switch Test the throttle safety ...

63 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 it...

64 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 62 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circui...

65 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. To use the emergency start strap:1. Open the clutch guard. 2. Push on the inner sheave of the cl...

66 OPERATION Reverse Operation Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described under the heading Altitude Settings . Always make sure the vehicle ...

67 OPERATION Reverse Operation Electronic Reverse (PERC t ) Disengaging Reverse Push the yellow reverse button on the handlebar 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 your vehicle is...

68 OPERATION Towing For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions. If the snowmobile becomes inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the tow rope to the ski spind...

69 MAINTENANCE Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 ″ (10 cm) off the ground.Remove the key and cover the machine. NOTE: Polaris has accessory covers and...

70 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 Weekly...

72 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 P...

73 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

74 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium grease at 500 miles (800 km) and annually or about every 1000 miles (1600 km) thereafter. See page 112 for the part numbers of Polaris products.The illustration shows the location of suspension and steer...

75 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the ...

76 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 pu...

77 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 synthetic chaincase o...

78 MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.In selecting a spark plug heat range for prod...

79 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. NOTE: Incorrect fuel mixture...

80 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 model may differ.1. Int...

81 MAINTENANCE Variable Exhaust System (VES) Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned. NOTE: To ensure m...

82 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 1000 miles (1600 km) and inspected for contamination. Plug ...

83 MAINTENANCE Fuel Filter/Fuel Lines Inspect the in-tank fuel filter (1) and fuel lines regularly. Give special attention to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Oil Filter Edge models have an oil filter that’s bu...

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

85 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or da...

86 MAINTENANCE Engine Cooling - Liquid Cooled Models 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...

87 MAINTENANCE Engine Cooling - Liquid Cooled Models 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 ...

88 MAINTENANCE Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If coolant becomes low in the tank, bleed the system of trapped air using the following procedure:1. Allow the system to cool completely, then loosen the bleed screw and fill the reservoir to the FULL COLD mark. Tighten...

89 MAINTENANCE Drive Chain Tension To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. Finger tighten the a...

90 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 (A). This distance, called brake lever reserve, should be no less than 1/2 ″ (1.3 cm). Brake pads must be replaced when ...

91 MAINTENANCE Brakes 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 Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on pa...

92 MAINTENANCE Brakes Brake Fluid Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir. Use only Polaris DOT 3 high temperature brake fluid. See page 112 for the part numbers of Polaris products. After opening a bottle of brake fluid, always discard any unuse...

93 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 possible. The reservoir must be in this position to min...

94 MAINTENANCE Headlights 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 headlight an...

95 MAINTENANCE Headlights 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 spring ret...

96 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment and Offset Clutch center distance and alignment (A) are crucial to maintaining optimu...

97 MAINTENANCE Clutch System 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. The following procedur...

98 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment 1. Loosen th...

99 MAINTENANCE Chain Tension Maintain the proper chain tension as outlined on page 89. Oil Level Maintain the oil level between the safe marks as indicated on the oil bottle (see page 59). Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Your tool kit will con...

100 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 For maximum performa...

101 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 ...

102 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...

103 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...

104 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a + .

105 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 ″ ...

106 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 Replacement 1. Raise and support the fron...

107 MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16 ″ (1.1 cm) is reached. Take the machine to your dealer for Hi-fax replacement. A 7/16 ″ (1.1 cm) A

108 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...

109 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. See page 112 for part numbers. Clutch and Drive System Remove the drive belt and store in a cool dry locat...

110 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...

111 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 ...

112 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2874439 VES II Synthetic 2-Cycle Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grea...

113 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 binding Driven clutchmal...

116 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily -Increase torsion spring preload-Increase rear shock compression damping by turning screwclockwise-Increase torsion spring wire diameter (see your dealer) Rides too s...

117 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...

118 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on...

119 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 ...

120 WARRANTY Warranty Coverage and Exclusions Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER...

121 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 co...

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

123 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 e...

124 INDEX A Accessories 44-47 . . . . . . . . . . . . . . . . . . . Air Box 23 . . . . . . . . . . . . . . . . . . . . . . . . B Bearings 109 . . . . . . . . . . . . . . . . . . . . . . . Before Starting the Engine 48-51 . . . . . . . Belt Troubleshooting 117 . . . . . . . . . . . . . Bleeding the C...

5 TABLE OF CONTENTS Introduction 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety 10 . . . . . . . . ...

7 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 The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the ...

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 The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these ...

10 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manua...

11 SAFETY Operator Safety WARNING 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 ...

12 SAFETY Operator Safety Stay Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become ent...

13 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably...

14 SAFETY Operator Safety Excessive Speed Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machi...

15 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

16 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...

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

18 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...

19 SAFETY Operator Safety Driving on Slippery Surfaces Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions.It’s dangerous to drive on ice or ...

20 SAFETY Operator Safety Maneuverability Control and maneuverability comes not only through the steering and skis, maximum control is achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to carry a load or a passenger. Maintenance Your Polaris ...

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

22 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) Speed in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60...

23 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the ...

24 SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: Passenger Warning Polaris PRO X snowmobiles are designed for one operator only. A “No Passenger” warning decal is located on the console: + +

25 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal on the lower dash. + WARNING AVERTISSEMENT

26 SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English. WARNING

28 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on the following pages. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of specific features on your machine. Accessories are ...

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

33 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...

34 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 ...

35 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX and Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. Front Springs For models without externally adjustable or revalvable shocks, the fr...

36 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs a...

37 THE PERFECT FIT PRO X Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the PRO X 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 suspe...

38 THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Torsion 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.T...

39 THE PERFECT FIT PRO X Rear Suspension Adjustments Clicker Shock The position sensitive clicker shock is available as an option on some models. Adjustments to the compression damping are made by turning the clicker knob (A) on the shock reservoir.Position #1 is the softest, or least compression da...

40 THE PERFECT FIT PRO X 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. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that c...

41 THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.Adjusting the RRSS...

42 THE PERFECT FIT PRO X Rear Suspension Adjustments Weight Transfer During Acceleration PRO X Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the PRO X rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your t...

43 THE PERFECT FIT Handlebar Adjustments Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/2” wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required....

44 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. NOTE: The accessory tether switch is available for all models. Order PN 2870668.Use only Polaris parts and accessor...

45 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: Before ...

46 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...

47 THE PERFECT FIT Accessories Wear Strips Polaris PRO X models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See you...

48 PRE-RIDE INSPECTIONS Before Starting the 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 Proper...

49 PRE-RIDE INSPECTIONS Before Starting the 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 ha...

50 PRE-RIDE INSPECTIONS Before Starting the 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 or...

51 PRE-RIDE INSPECTIONS Before Starting the 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 com...

52 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine. n Tether Switch: If your machine has a tether switch, make sure the engine shuts off w...

53 OPERATION Starting the Engine Starting a Cold Engine 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 abruptly to star...

54 OPERATION Starting the Engine Starting a Warm Engine 1. Turn key to ON . 2. Pull kill switch (shut-off switch) up to RUN . 3. Grasp starter handle and pull slowly until recoil engages; then pull to start. If the engine does not start on the first pull, slightly depress the throttle with your left...

55 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 We recommend the use of Polaris VES two-cycle oil in all snowmo...

57 OPERATION Fuel Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area w...

58 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris snowmobile engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline, but a higher octane fuel (premium 91 octane) is preferre...

59 OPERATION Fuel Fuel Reserve Capacity There are approximately two gallons of fuel left in the tank when the fuel gauge indicates reserve ( RES). Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per g...

60 OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 55 for oil recommendations.When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may b...

61 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...

62 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 the ON position. Throttle Safety Switch Test the throttle safety ...

63 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 it...

64 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 62 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circui...

65 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. To use the emergency start strap:1. Open the clutch guard. 2. Push on the inner sheave of the cl...

66 OPERATION Reverse Operation Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described under the heading Altitude Settings . Always make sure the vehicle ...

67 OPERATION Reverse Operation Electronic Reverse (PERC t ) Disengaging Reverse Push the yellow reverse button on the handlebar 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 your vehicle is...

68 OPERATION Towing For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions. If the snowmobile becomes inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the tow rope to the ski spind...

69 MAINTENANCE Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 ″ (10 cm) off the ground.Remove the key and cover the machine. NOTE: Polaris has accessory covers and...

70 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 Weekly...

72 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 P...

73 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

74 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium grease at 500 miles (800 km) and annually or about every 1000 miles (1600 km) thereafter. See page 112 for the part numbers of Polaris products.The illustration shows the location of suspension and steer...

75 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the ...

76 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 pu...

77 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 synthetic chaincase o...

78 MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.In selecting a spark plug heat range for prod...

79 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. NOTE: Incorrect fuel mixture...

80 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 model may differ.1. Int...

81 MAINTENANCE Variable Exhaust System (VES) Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned. NOTE: To ensure m...

82 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 1000 miles (1600 km) and inspected for contamination. Plug ...

83 MAINTENANCE Fuel Filter/Fuel Lines Inspect the in-tank fuel filter (1) and fuel lines regularly. Give special attention to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Oil Filter Edge models have an oil filter that’s bu...

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

85 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or da...

86 MAINTENANCE Engine Cooling - Liquid Cooled Models 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...

87 MAINTENANCE Engine Cooling - Liquid Cooled Models 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 ...

88 MAINTENANCE Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If coolant becomes low in the tank, bleed the system of trapped air using the following procedure:1. Allow the system to cool completely, then loosen the bleed screw and fill the reservoir to the FULL COLD mark. Tighten...

89 MAINTENANCE Drive Chain Tension To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. Finger tighten the a...

90 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 (A). This distance, called brake lever reserve, should be no less than 1/2 ″ (1.3 cm). Brake pads must be replaced when ...

91 MAINTENANCE Brakes 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 Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on pa...

92 MAINTENANCE Brakes Brake Fluid Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir. Use only Polaris DOT 3 high temperature brake fluid. See page 112 for the part numbers of Polaris products. After opening a bottle of brake fluid, always discard any unuse...

93 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 possible. The reservoir must be in this position to min...

94 MAINTENANCE Headlights 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 headlight an...

95 MAINTENANCE Headlights 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 spring ret...

96 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment and Offset Clutch center distance and alignment (A) are crucial to maintaining optimu...

97 MAINTENANCE Clutch System 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. The following procedur...

98 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment 1. Loosen th...

99 MAINTENANCE Chain Tension Maintain the proper chain tension as outlined on page 89. Oil Level Maintain the oil level between the safe marks as indicated on the oil bottle (see page 59). Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Your tool kit will con...

100 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 For maximum performa...

101 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 ...

102 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...

103 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...

104 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a + .

105 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 ″ ...

106 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 Replacement 1. Raise and support the fron...

107 MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16 ″ (1.1 cm) is reached. Take the machine to your dealer for Hi-fax replacement. A 7/16 ″ (1.1 cm) A

108 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...

109 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. See page 112 for part numbers. Clutch and Drive System Remove the drive belt and store in a cool dry locat...

110 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...

111 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 ...

112 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2874439 VES II Synthetic 2-Cycle Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grea...

113 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 binding Driven clutchmal...

116 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily -Increase torsion spring preload-Increase rear shock compression damping by turning screwclockwise-Increase torsion spring wire diameter (see your dealer) Rides too s...

117 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...

118 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on...

119 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 ...

120 WARRANTY Warranty Coverage and Exclusions Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER...

121 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 co...

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

123 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 e...

124 INDEX A Accessories 44-47 . . . . . . . . . . . . . . . . . . . Air Box 23 . . . . . . . . . . . . . . . . . . . . . . . . B Bearings 109 . . . . . . . . . . . . . . . . . . . . . . . Before Starting the Engine 48-51 . . . . . . . Belt Troubleshooting 117 . . . . . . . . . . . . . Bleeding the C...