Polaris 800 Switchback - 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 indicates a potential personal in...

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alco...

10 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to sta...

11 SAFETY Operator Safety Riding Apparel Be prepared, be warm and be com- fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22. WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving par...

12 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For y...

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 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...

15 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...

16 SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are...

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 Driving in Hilly Terrain WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly te...

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

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

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

22 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2...

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

24 SAFETY Safety Decals and Locations Hot Surface Warning The hot surface warning is located near the rear of the tunnel: WARNINGHOT SURFACE - DO NOT TOUCHBurn may result. Entire top of tunnel may be hot.Install only accessories specifi- cally approved for this model by Polaris. Track Warning The tr...

25 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console beside the steering post: WARNINGReverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look behind before and...

27 FEATURES Not all models are equipped with all features shown. 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper (do not use for pulling or dragging the snow- mobile) 4. Hood 5. Headlight 6. Windshield 7. Handlebar 8. Operator Seat 9. Taillight 10. Rear Bumper 11. Snow Flap 12. Susp...

29 FEATURES Cargo Area The maximum weight capacity for the cargo area is 15 lbs. (7 kg). Install only accessories specifically approved for this model by Polaris. Always secure cargo before operating. Do not exceed the cargo area weight limit. Adjustable Headlights Adjust the headlight beam by movin...

30 FEATURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog (if equipped) 2 Digital Gauge 3 CHECK ENGINE Indicator (carb models) 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Item 1 RPM or Speed Altitud...

31 FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( + ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measureme...

32 FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Per- formance, Engine and History. Each program will remain in the display until another is selected. TIP: The analog will always display either MPH or engine RPM (whichever set- t...

33 FEATURES Instrumentation MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. Press and hold the SET button for two seconds. If the s...

35 FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature senso...

37 FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service i...

38 FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE"...

39 FEATURES Instrumentation MFD Battery Replacement (models with clocks) If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the under- side of the hood. 2. Locate the black battery compart- men...

41 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We ...

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

43 THE PERFECT FIT Front Suspension Adjustments Shock Compression Damping (Premium Shocks) Turn the adjuster to make adjustments to the compression damping. When adjusting, we recommend that you turn the adjuster only one click, then test ride. Always adjust both shocks equally. The standard setting...

44 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 design...

45 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines the position at which the spring pre- load should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are...

46 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension tor- sion 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 ...

47 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To determine sag, commonly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload. TIP: This is only an ...

48 THE PERFECT FIT 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 req...

50 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Compression Damping (Premium Shock) Turn the adjuster on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster one click, then test ride...

51 THE PERFECT FIT 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 suspension...

52 THE PERFECT FIT Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front to...

53 THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for control- ling weight transfer during accel- eration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. To decrease weight tran...

54 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. Handlebar Angle 1. Loosen the fo...

55 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 requ...

56 THE PERFECT FIT Traction Products Studs Before equipping your machine 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 im...

57 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...

58 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...

59 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or ...

60 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 I (1.3 cm). A smaller distance indicates low brake fluid level o...

61 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever2. Parking Brake Lever Lock 3. Master Cylinde...

62 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System WARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be ...

63 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...

64 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. S...

65 OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position.2. Pull the engine stop switch up to th...

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

67 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 71. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your deale...

69 OPERATION Fuel Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.• Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling.• Do not overfill the tank. Do not fill the tank ne...

70 OPERATION Fuel Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). NOTICE: Operating ...

71 OPERATION n Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 67 for oil recommendations. Low Oil Level Maintaining the proper oil level will p...

73 OPERATION Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle l...

74 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft ...

75 OPERATION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed. • Shift to or from r...

76 OPERATION Electronic Reverse (PERC t ) Engaging Reverse 1. Stop the snowmobile and leave the engine idling.2. Make sure the area behind your vehicle is clear.3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and sta...

77 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 I (10 cm) off the ground. Remove the key and cover the machine. Towing Do not use the front bumper to...

78 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...

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

80 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris d...

83 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 79 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 mile...

84 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly...

85 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change ...

86 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface.2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. The sea...

87 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. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your ...

88 MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. CAUTION! A hot exha...

89 MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap.2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm).5. Reinstall the spark...

90 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing....

91 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper- ated at extremely low temperatures, greater p...

92 MAINTENANCE Cooling System Coolant High Temperature Indicator Light CAUTION! Steam and hot liquids will cause burns to your skin. Never remove the pressure cap when the engine is warm or hot. The high temperature indicator light will illuminate when engine cool- ant temperature becomes too hot fo...

93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly...

94 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Nev...

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

96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 60. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 I ). A kit is available for replacing brake pads. See ...

97 MAINTENANCE Brakes Brake Fluid WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to dr...

98 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and...

99 MAINTENANCE Lights Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the head...

100 MAINTENANCE Lights Taillight/Brakelight Replacement 1. Remove the screws securing the taillight lens. Remove the lens.2. Push the bulb inward and turn it counterclockwise to remove it.3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it. 4. Reinstall the taillight lens.

101 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift patt...

102 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. ...

103 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 I (3.2 cm). Drive Belt Adjustmen...

104 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counter- clockwise 1/4 turn by hand to ensure...

105 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. To ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them. If r...

106 MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Matte Clear Coat Cleaning Matte finish products are prone to trapping dirt, oils and o...

107 MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rea...

108 MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment ...

109 MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 108. If the track needs adjustment: 6. Loosen the rear idler shaft bolt.7. Loosen the locknuts. 8. Tighten or ...

110 MAINTENANCE Track 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 machine with the track off the ground.2. Start the engine and...

111 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. + + + + +

112 MAINTENANCE Steering System Ski Alignment WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead posi...

113 MAINTENANCE Steering System n Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the ori...

114 MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove ( + ). Do not operate the snowmobile if slide thickness measures less than 7/16 I (1.1 cm)....

115 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 118 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts wit...

116 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch co...

117 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Transporting the Snowmobile Whenever the snowmobile is transported: ...

118 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.) 2877884 VES Gold Plus Synthet...

119 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- ating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Dr...

122 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 46). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Rides t...

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

124 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates ...

125 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...

126 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 ...

128 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...

129 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 ...

130 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...

133 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...

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 55Adjustable Headlights . . . . . . . . . . . 29Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Bearings . . . . . . . . . . . . . . . . . . . . . 116 Brake Components. . . . . ...

4 TABLE OF CONTENTS Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety 8 . . . . . . . . . ....

5 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 ...

6 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...

7 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 ...

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 symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

9 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 o...

10 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...

11 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...

12 SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Riding Apparel Be aware of the weather forecast and especiall...

13 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...

14 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...

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

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 Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutc...

19 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...

20 SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer a...

21 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...

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

23 SAFETY Safety Decals and Locations Track/Seat Warning The track/seat warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Some Polaris snowmobiles are eq...

24 SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a Polaris dealer for a ...

25 FEATURES AND CONTROLS Controls 1. Fuel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may include indicator/warning lights) 5. Tachometer (may include indicator/warning lights) 6. Engine Stop Switch (see page 59) 7. Throttle Control 8. Recoil Starter Handl...

26 FEATURES AND CONTROLS Controls Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of features on your machine.Accessories are available f...

27 FEATURES AND CONTROLS Features 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage Compartment 7. Taillights 8. Snow Flap 9. Track 10. Suspension 11. Trailing Arm 12. Nosepan 13. Front Bumper 14. Skis 8 4 3 2 1 13 5 7 9 10 12 11 14 6

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

30 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...

31 THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and i...

32 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 the springs on both the left and right sides of the machine are...

33 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX or RydeFX SOLO 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 fron...

34 THE PERFECT FIT Rear Suspension Adjustments Rear Suspensions 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...

35 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension 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 this measurement with no rider and with the rear suspen...

36 THE PERFECT FIT 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.The foll...

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

38 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust the handlebar for a personal fit.1. Remove the handlebar cover to access the four adjuster block bolts (A). 2. Using a 7/16 ″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn the ha...

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

40 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 ...

42 THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel or cooler damage, wear strips must be installed whenever track studding is used. See your dealer for more information.Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction ac...

43 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...

44 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...

45 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...

46 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...

47 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 start the engine. n Lighting Check: Check the headlight (high and low beam), taillight, and brake light for normal o...

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

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

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

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

53 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...

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

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

56 OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 51 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...

57 OPERATION Oil Low Oil Level Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 51 for oil recommendations.The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See you...

58 OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.Carburetor...

59 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 ...

60 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...

61 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 59 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circui...

62 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machines equipped with electric start have a recoil for emergency starting. On manual start models, an emergency start strap is provided for use if the recoil starter system fails. ...

63 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 below. Always make sure the vehicle is stopped and the engine is ru...

64 OPERATION 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 ″ (20 cm) off the ground.Remove the key and cover the machine. NOTE: Polaris has accessory covers and t...

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

66 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...

68 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...

69 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

70 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 110 for the part numbers of Polaris products.The illustration shows the location of suspension and ...

71 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 ...

72 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...

73 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...

74 MAINTENANCE General 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...

76 MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. NOTE: These illustrations are general representations. Your mod...

77 MAINTENANCE General Maintenance Variable Exhaust System (V.E.S.) Maintenance of the V.E.S. is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles, bring the machine to an authorized Polaris dealer to have the V.E.S. disassembled, inspected, and cleaned. NO...

78 MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for con...

79 MAINTENANCE General 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 The oil filter shoul...

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

81 MAINTENANCE General 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 ret...

82 MAINTENANCE General Maintenance Engine Cooling - Liquid Cooled Models Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models. If the engine coolant reaches a certain temperature, the switch compl...

83 MAINTENANCE General Maintenance Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If the pressure cap needs replacement, contact your dealer for the correct part. Use of a non-standard pressure cap will not allow the cooling system to function properly. 1. Remove the pressure cap ...

84 MAINTENANCE General 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. ...

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

86 MAINTENANCE General Maintenance Brake Components Air cooled model Liquid cooled model 1. Brake Caliper 2. Chaincase 3. Brake Disc 4. Backing Plate 5. Brake Pad Material (Replace when thickness is less than 1/16 ″ ). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brak...

87 MAINTENANCE General Maintenance Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid.We recommend the use of Polaris DOT 3 hi...

88 MAINTENANCE General Maintenance 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 po...

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

90 MAINTENANCE General Maintenance NOTE: Avoid touching 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 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer...

91 MAINTENANCE General 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 t...

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

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

94 MAINTENANCE General Maintenance 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 Polari...

95 MAINTENANCE General Maintenance Torque Stop Your snowmobile is equipped with an engine torque stop (1). Periodically check the torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010 ″ to a maximum of .030 ″ from the engine case (2). Adjust ...

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

97 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 ...

98 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 brake...

99 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. Th...

100 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the following illustrations. Edge IFS Steering System + + + + + + +

101 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 ″ ...

102 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...

103 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 ″ is reached. Take the machine to your dealer for Hi-fax replacement.If excessive Hi-fax wear occurs due to poor snow conditions, additional wheel ki...

104 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. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and pl...

105 MAINTENANCE Extended Storage Controls and Linkage All bushings, spindle shafts, tie rod ends, and cables should receive a light coat of oil or grease. Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to pre...

106 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 110 for the part numbers of Polaris products.Replace worn or frayed electrical...

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

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

109 MAINTENANCE Battery Installation 1. Place the battery in its holder. Attach the hold down strap. 2. Install the battery vent line. It must be free from obstructions and securely installed. Route the vent line properly to prevent kinks and to allow for proper drainage. 3. Connect and tighten the ...

110 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Oil (gal.) 2874438 VES II Synthe...

111 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Verify sag dimension (see set-up decal or page 35). Adjust torsion spring blocks (page 36) or install optional torsion springs to achieve correct sag dimensions. -...

112 TROUBLESHOOTING Belt Wear/Burn Troubleshooting 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 weather ...

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 engine operating RPM during accelera- tion or load variations Drive clutch binding Driven clutc...

116 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...

117 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 ...

119 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 c...

120 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...

121 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...

122 INDEX A Accessories 39-42 . . . . . . . . . . . . . . . . . . . Airbox 22 . . . . . . . . . . . . . . . . . . . . . . . . . B Battery 106-108 . . . . . . . . . . . . . . . . . . . . Battery Connections 108 . . . . . . . . . . . . . . Battery Fluid 107 . . . . . . . . . . . . . . . . . . . . Batt...