Polaris 900 RMK - Manuals

4 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow th...

5 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...

6 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...

7 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...

8 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 78 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. ...

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

10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under most conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for prop...

11 SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment th...

12 SAFETY Operator Safety Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be al...

13 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...

14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche be...

15 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 ...

16 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 ter...

17 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...

18 SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models...

19 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...

20 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) Wind Speed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Eq...

21 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...

+ 22 SAFETY Safety Decals and Locations Track Warning Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” Warning +

23 SAFETY Safety Decals and Locations Reverse Warning Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: S Look behind before and while backing up. S Avoid sharp turns. S Shift to or from reverse only when stopped....

24 SAFETY Safety Decals and Locations Operation Warning S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is miss- ing, contact a Polaris dealer for a replacement. S This vehicle is capable of high speeds. Buried objects or un...

10 4 3 2 1 14 6 8 12 11 13 15 9 7 5 7 25 FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Side Shield 6. Seat 7. Storage Compartment 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Suspension 12. Track 13. Nosepan 14. Front Bumper 15. Skis

+ + + 27 FEATURES Seat Storage Compartment Lift the seat lever ( + ) and lift the seat to access the under-seat storage area. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left (to lower the beam) or to the right (to raise the beam). Access Panel The access panel ( + ...

28 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. Choosing the Best RIDER SELECT t Position Position Riding Style 123 Relaxed Trail Riding Rider weight is slightly behind the center...

29 FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile.2. Pr...

30 FEATURES Detonation Elimination Technology (D.E.T.) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. DET Troubleshooting Use this chart to determine causes and solu...

31 FEATURES MFD Components Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator MFD Digital Display Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Le...

32 FEATURES MFD Settings With the engine running, use the MFD Control Switch (1) to set the MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of measurement. While viewing a screen th...

33 FEATURES MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting is selected) re...

34 FEATURES MFD Digital Display Programs Performance Program Odometer Setting The odometer records the vehicle’s total distance traveled since manufacture. The odometer cannot be reset. Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour star...

35 FEATURES MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level. On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air tem...

37 FEATURES MFD Digital Display Programs Engine Program Hour Meter The hour meter records the total hours of engine operation since manufacture. This meter cannot be reset. Engine Temperature A thermometer measures water temperature, giving an indication of engine temperature. History Program The Hi...

38 FEATURES MFD Digital Display Programs History Program 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” will fl...

39 FEATURES MFD Battery Replacement 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 underside of the hood. 2. Locate the black battery compartment (A). It has a red wire and a brown wire ...

1 2 4 3 3 5 41 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and...

1 3 2 4 5 1 3 4 5 2 42 THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 110 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock...

1 43 THE PERFECT FIT IQ Front Suspension Adjustments Shock Compression Damping (RMK Standard Only) Adjustments to the compression stiffness of RYDE FX shocks can be made by turning the adjustment screw located near the base of the shock (1). This adjustment is the easiest to perform and it should be...

B A 44 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload (RMK Premium and Switchback Only) NOTE: The shocks are similar in appearance. The RMK Premium shock is shown. Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-...

45 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving (RMK Premium and Switchback Only) Some shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on shocks requires special tools a...

46 THE PERFECT FIT IQ 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 design...

47 THE PERFECT FIT IQ 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 sus...

48 THE PERFECT FIT IQ 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. 1. S...

49 THE PERFECT FIT IQ Rear Suspension Adjustments Rear Track Shock Compression Damping See pages 50 and 51 for additional information.1. Turn rear track shock screw clockwise to stiffen compression (RMK Standard only) 2. Turn the rear track shock knob clockwise for a softer ride.3. Turn the rear tra...

1 50 THE PERFECT FIT IQ Rear Suspension Adjustments RMK Standard Rear Track Shock The standard RMK rear track shock is an Arvin RYDE FX shock that allows for adjustments to the compression valving. Adjustments are made by turning the adjustment screw (1) located near the base of the shock.In half-tu...

1 2 51 THE PERFECT FIT IQ Rear Suspension Adjustments RMK Premium Rear Track Shock The ARVIN Rapid Adjust shock is available as an option on RMK models. Turn the adjustment knob (1) on the shock reservoir to make adjustments to the compression damping.Positions are labeled on the shock. When adjusti...

52 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 28. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster bloc...

53 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. NOTE: The accessory tether switch is available for all models. Order PN 2870668. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved p...

54 THE PERFECT FIT Traction Products (Switchback only) 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 warranties are void if track damage or failure ...

55 THE PERFECT FIT Traction Products (Switchback only) 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 maint...

57 PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and re...

58 PRE-RIDE INSPECTIONS Before Starting the Engine n Recoil Rope Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement. n Brakes Always check the following items...

4 3 1 2 59 PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock Use the park 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 Lever 2. Park Brake Lever Lock 3. Master Cylinder...

60 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, remove any ice and snow build-up that may be obstructing the steering linkage. n Track WARNING Operating the snowmobile with a damage...

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

62 OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 57. Do not d...

63 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...

64 OPERATION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn’t go down, contact your dealer immediately. Var...

66 OPERATION Slide Rail and Track Cooling CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track s...

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

68 OPERATION Fuel For peak performance, 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 fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in ...

69 OPERATION Oil n Low Oil Level The low oil indicator light will alert the operator if the oil level is low. Add oil before further operation of the snowmobile. See page 64 for oil recommendations. CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine dam...

70 OPERATION n Engine Stop Switch Push down on the engine stop switch (A) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is rem...

71 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 le...

72 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 70 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

73 OPERATION Emergency Starting If the recoil starter system fails, an emergency start strap is provided in the tool kit.1. Open the hood.2. Remove the left side panel.3. Remove the air box (pull aggressively). 4. Using the belt removal tool, follow the directions on the air box to relieve belt tens...

74 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. WARNING 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 transmission if shifting is ...

75 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 ″ (10 cm) off the ground.Remove the key and cover the machine. Towing WARNING Objects towed with a rope...

76 MAINTENANCE Emission Control Information Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory--installed emissions information hangtag. These items are required by U.S. Environmental Protection Agency regulations. Th...

77 MAINTENANCE Emission Control Information Owner’s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 129, and read the maintenance section of your owner’s manual. You are responsible for ensuring that the specified maintenance is performed, including the emission...

78 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 131.The recommende...

79 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...

82 MAINTENANCE Lubrication Front Suspension The Fusion front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before ...

+ + 83 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 lig...

1 2 3 84 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). C...

4 85 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. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the...

86 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION Using non-recommended...

2 87 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. WARNING A hot exhaust syst...

1 2 88 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.1. Intake Foam Filters/Pre-filter 2. Plenum

89 MAINTENANCE Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Lines Ins...

90 MAINTENANCE Oil Filter Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch.Have your dealer perform the filter change and bleeding operation....

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

92 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the ECU. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on. If you must drive your machine after the high...

93 MAINTENANCE Cooling System Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your skin. ...

1 2 94 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. ...

95 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile.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). Br...

96 MAINTENANCE Brakes Brake Components 1. Brake Caliper 2. Brake Disc 3. Backing Plate 4. Brake Pad Material (Replace when thick- ness is less than 1/16 ″ /1.5mm). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 95), bring the machi...

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 dro...

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 ...

2 1 3 99 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. Removing Halogen Bulbs 1. Remove the plenum covering fro...

A 100 MAINTENANCE Clutch System WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.All clutch maintenance and repairs must be performed by an authorized Pol...

1 101 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...

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

A B 1 .010 ″ -.030 ″ (.25-.75mm) 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 on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”...

104 MAINTENANCE Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. Maintenance Items The tools and maintenance items ...

1 105 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They 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 hoi...

106 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 i...

107 MAINTENANCE Track Maintenance Track Tension I f the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A).7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on th...

1 108 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 a...

+ + + + 109 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

X Y 10 ″ 10 ″ 110 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 straig...

1 111 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...

A 7/16 ″ (1.1 cm) 112 MAINTENANCE Suspension Maintenance n Slider Wear Measure slider thickness at several points along the rail. Have your dealer replace the slider when it’s worn down to the top of the wear groove (A). Do not operate the snowmobile if slider thickness measures less than 7/16 ″ (1....

113 MAINTENANCE Suspension Maintenance n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a we...

114 MAINTENANCE Suspension MaintenanceExtended 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 117 for the part numbers of Polaris products. Cleaning and Preservation Prope...

115 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...

116 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. Track and Suspension Moderate track tension should be maintained dur...

117 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.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Go...

118 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 Drive clutch binding S SEE YOUR DEALER. RPM during acceleration or ...

121 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Verify sag dimension (see page 47). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. - Increase shock compressio...

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

123 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...

124 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 ...

126 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...

127 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...

128 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...

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

131 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. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)...

133 INDEX A Access Panel 27 . . . . . . . . . . . . . . . . . . . Accessories 53 . . . . . . . . . . . . . . . . . . . . Adjustable Headlights 27 . . . . . . . . . . . . Avalanches 14 . . . . . . . . . . . . . . . . . . . . B Bearings 115 . . . . . . . . . . . . . . . . . . . . . Before Starting the...

7 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow th...

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 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...

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 Follow the recommended maintenance program outlined beginning on page 72 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention....

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

13 SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment th...

14 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. Rider Capacity Your Polari...

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 Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche be...

17 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 ...

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 ter...

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 WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models...

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 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...

+ 24 SAFETY Safety Decals and Locations Track Warning Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” Warning +

25 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the windshield: Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: S Look behind before and while back...

10 4 3 2 1 14 6 8 12 11 13 15 9 7 5 7 27 FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Side Shield 6. Seat 7. Storage Compartment 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Suspension 12. Track 13. Nosepan 14. Front Bumper 15. Skis

29 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious inju...

1 1 30 FEATURES Seat Storage Compartment Lift the seat lever (1) and lift the seat to access the under-seat storage area. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right. Access Panel The access panel (1) is provided for cleaning out debris and making repa...

31 FEATURES Detonation Elimination Technology (D.E.T.) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. DET Troubleshooting Use this chart to determine causes and solu...

32 FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Servic...

33 FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch (1) to set the MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of measurement. While vie...

34 FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting...

35 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the ho...

36 FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/--300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard an...

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

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” will fl...

39 FEATURES Instrumentation MFD Battery Replacement 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 underside of the hood. 2. Locate the black battery compartment (A). It has a red wire a...

40 FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or ...

1 2 4 3 41 THE PERFECT FIT IQ Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend startin...

1 2 3 4 5 42 THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 103 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spri...

A 43 THE PERFECT FIT IQ Front Suspension Adjustments Shock Compression Damping (Standard Only) Adjustments to the compression stiffness of Indy Select shocks can be made by turning the adjustment screw (Select) located near the base of the shock (A). This adjustment is the easiest to perform and it ...

C B 44 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload (Premium Only) 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...

45 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving (Premium Only) Some shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on shocks requires special tools and a sound knowledg...

46 THE PERFECT FIT IQ 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 design...

47 THE PERFECT FIT IQ 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 sus...

48 THE PERFECT FIT IQ 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 f...

A 49 THE PERFECT FIT IQ Rear Suspension Adjustments Rear Shocks 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.Locate the adjustment screw...

A 50 THE PERFECT FIT IQ Rear Suspension Adjustments Rear Shocks ARVIN Rapid Adjust Shock The ARVIN Rapid Adjust shock is available as an option on some models. Turn the Rapid Adjust knob (A) on the shock reservoir to make adjustments to the compression damping.Positions are labeled on the shock. Whe...

51 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 29. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster bloc...

52 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. NOTE: The accessory tether switch is available for all models. Order PN 2870668. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved p...

54 PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and re...

55 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 ″ (1.3 cm). A smaller distance indicates low brake fluid level o...

4 3 1 2 56 PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock Use the park 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 Lever 2. Park Brake Lever Lock 3. Master Cylinder...

57 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...

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

59 OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 54. Do not d...

60 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...

61 OPERATION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn’t go down, contact your dealer immediately. Var...

63 OPERATION Slide Rail and Track Cooling CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track s...

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

65 OPERATION Fuel For peak performance, 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 fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in ...

66 OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check the oil level in the bottle. Add oil before further operation of the snowmobile. See page 61 for oil recommendations. n Low Oil Level Always maintain the oil level a...

67 OPERATION n Engine Stop Switch Push down on the engine stop switch (A) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is rem...

68 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 le...

69 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 67 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

70 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. WARNING 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 transmission if shifting is ...

71 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 ″ (10 cm) off the ground.Remove the key and cover the machine. Towing WARNING Objects towed with a rope...

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

73 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...

76 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...

77 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

+ + 78 MAINTENANCE Lubrication Front Suspension The Fusion front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and bef...

A B C 79 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 73. Maintain the oil level between the safe marks on the dipstick (A). Change the chaincase oil after the first 500 miles (800 km), then every 1000 mil...

80 MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION U...

2 81 MAINTENANCE General 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. WARNIN...

1 2 82 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.1. Intake Foam Filters/Pre-filter 2. Plenum

83 MAINTENANCE General Maintenance Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel ...

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

85 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the ECU. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on. If you must drive your machine after the...

86 MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your s...

A B 87 MAINTENANCE General Maintenance Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the ...

88 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile.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 ″...

89 MAINTENANCE General Maintenance Brake Components 1. Brake Caliper 2. Brake Disc 3. Backing Plate 4. Brake Pad Material (Replace when thick- ness is less than 1/16 ″ /1.5mm). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 88), br...

90 MAINTENANCE General Maintenance 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...

91 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. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an ...

2 1 3 92 MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs 1. Remove the plenum covering from the headlight assembly. 2. Lift the rubber boot to expose...

A 93 MAINTENANCE General Maintenance Clutch System WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.All clutch maintenance and repairs must be performed b...

A 94 MAINTENANCE General Maintenance 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 ...

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

A B 1 .010 ″ -.030 ″ (.25-.75mm) 96 MAINTENANCE General Maintenance n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1...

3 1 2 4 5 6 7 97 MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile.1. Emergency Start Strap2. Phillips Screwdriver3. L-Wrench4. Spark Plug Wrench5. Wrench6. Flat Screwdriver7. Box End ...

A 98 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They 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 hois...

99 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 is...

100 MAINTENANCE Track Maintenance Track Tension I f the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A).7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on th...

A 101 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 a...

+ + + + 102 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

X Y 10 ″ 10 ″ 103 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 straig...

A 104 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...

A 7/16 ″ (1.1 cm) 105 MAINTENANCE Suspension Maintenance n Slider Wear Measure slider thickness at several points along the rail. Have your dealer replace the slider when it’s worn down to the top of the wear groove (A). Do not operate the snowmobile if slider thickness measures less than 7/16 ″ (1....

106 MAINTENANCE Suspension MaintenanceExtended 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 109 for the part numbers of Polaris products. Cleaning and Preservation Prope...

107 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...

108 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. Track and Suspension Moderate track tension should be maintained dur...

109 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.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Go...

110 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 Drive clutch binding S SEE YOUR DEALER. RPM during acceleration or ...

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

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

115 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...

116 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 ...

118 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...

119 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...

120 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...