Polaris FST Classic - Manuals

5 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 the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may...

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 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 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 Follow the recommended maintenance program outlined beginning on page 87 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. ...

10 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. 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...

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

12 SAFETY Operator Safety Riding Apparel Be prepared, be warm and be comfortable 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 parts ...

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 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...

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 snowmobile, 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 a...

18 SAFETY Operator Safety Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serio...

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. Driving in too little snow will result in excessiv...

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 snowmobile 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 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...

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 “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the console below the steering post: WarmingThis vehicle is designed for operator only.“NO PASSENGER” Passenger Warning Snowmobiles designed for an operator and one pas...

25 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. S Avoid sharp turns. S Shift to or from reverse only when stopped. S ...

26 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...

27 FEATURES 1. Front Bumper 2. Hood 3. Headlight 4. Passenger Lumbar Adjuster (Touring) 5. Windshield 6. Handlebar 7. Operator Seat 8. Passenger Seat (Touring) 9. Passenger Grab Handle 10. Grab Handle Heater Switch (Touring) 11. Trunk Cover or Storage Compartment 12. Taillights 13. Rear Bumper 14. S...

+ 29 FEATURES Passenger Seat (Touring) The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob (A). Storage Compartments Trunk (Touring) Open the trunk cover (B) to access the rear storage compartment. The passenger seat and trunk cove...

+ + 30 FEATURES Radiator Compartment Access Panel The access panel ( + ) is provided for cleaning debris from the radiator. Cargo Rack (Switchback) The maximum weight capacity for the cargo rack ( + ) is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit. Do no...

31 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. Some models have five (5) adjustment positions. Other models have seven (7) positions. WARNING If your snowmobile has five adjustme...

32 FEATURES RIDER SELECT Adjustable Steering System Adjusting RIDER SELECT 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. St...

33 FEATURES Engine Management System Malfunction Indicator Lamp (MIL) The MIL (Check Engine Indicator) will illuminate when the ECU detects a problem with engine management system components. If this occurs, see your dealer for service immediately.The MIL will blink in the event that the ECU detects...

34 FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (FST) if the following conditions are encountered. Vehicle Speed is Limited Cause Function Maximum Speed MPH (km/h) Result Reverse is selected Reverse 12 (19) ...

36 FEATURES Detonation Elimination Technology (DET) (Turbo Models) 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. NOTE: Engine performance will be reduced if fuel wi...

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

38 FEATURES Instrumentation MFD Settings MFD settings can be made with the engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge. The gauge will illuminate for about 90 seco...

39 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...

40 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...

41 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 and...

42 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...

43 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...

44 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...

1 2 4 3 46 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 tra...

47 THE PERFECT FIT IQ Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of ArvinMeritor MPV Select shocks can be made by turning the adjustment screw ( + ) located near the base of the shock. This adjustment is the easiest to perform and it should be considered firs...

48 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving (Switchback) The shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving requires special tools and a sound knowledge of mechanic...

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

50 THE PERFECT FIT Switchback 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 suspension at full exte...

51 THE PERFECT FIT Switchback Rear Suspension 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. A. Soft ...

52 THE PERFECT FIT Switchback Rear Suspension Rear Track Shock Compression Damping A. Turn rear track shock screw clockwise to stiffen compression.B. Turn the rear track shock knob clockwise for a softer ride.C. Turn the rear track shock knob counter clockwise for a stiffer ride. B C A

L 53 THE PERFECT FIT Switchback Rear Suspension Rear Shocks When adjusting, we recommend that you turn the adjuster slightly, then test ride. The recommended setting for this shock is eight (8) clicks counter-clockwise. FOX Zero Pro XC Shock The FOX Zero Pro XC shock is standard on the Switchback mo...

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

55 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 3. Subtract Y from X and you will have the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). The correct amount of SAG for the FAST M-10 rear suspension is 3-4 inches (8-10 cm). If the measured sag is...

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

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

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

60 THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 31. Use the following steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover (A) to expose the handlebar and the four adjuster block bolts (B). NOTE: If equipped...

61 THE PERFECT FIT Passenger Grab Handle Adjustment (Touring) On some Touring models the position of the passenger grab handles can be adjusted for rider preference. To make an adjustment:1. Unscrew and remove the knob assemblies (A) that secure the grab handles. 2. Reposition the grab handles to on...

62 THE PERFECT FIT Traction Products Studs Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products.Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from im...

63 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...

65 PRE-RIDE INSPECTIONS Check 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 ...

66 PRE-RIDE INSPECTIONS Check 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 ...

67 PRE-RIDE INSPECTIONS Check 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 l...

D C A B 68 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Park Brake Lever Lock Use the park brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.A. Brake LeverB. Park Brake Lever LockC. Master C...

69 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Track Inspection WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the v...

70 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following item...

71 PRE-RIDE INSPECTIONS Check After Starting the Engine 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 L...

73 OPERATION Fuel Safety 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...

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

75 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 65. Do not d...

76 OPERATION Emergency Starting If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions below. WARNING Improperly connecting or disconn...

79 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 ...

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

82 OPERATION Electronic Reverse (PERC 4 t ) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum engine speed when operating in reverse will be 6000 RPM. WARNING Improper reverse operation, even at low speeds, may cause loss of control, result...

83 OPERATION n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 80 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit A...

84 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 snowmobile. Towing WARNING Objects towed with a r...

85 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 control information (ECI) lab...

86 MAINTENANCE Emission Control Information Owner’s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 147, and read the maintenance section of your owner’s manual. You are responsible for ensuring that the specified maintenance is performed, including the emission...

87 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 149.The recommende...

88 MAINTENANCE Periodic Maintenance Interval Table D = Perform Service " = Replace DAILY or PRE- RIDE INITIALLY mi (km) YEARLY or EVERY mi (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Stop Switch 71 Test for proper operation. Do not operate if switches ...

91 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Always change the oil filter whenever changing oil. See page 133 for the part numbers of Polaris products. Performance Synthetic 4-Stroke (PS-4) Oil Pola...

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

93 MAINTENANCE Engine Oil n Oil Level Check 6. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. 7. Remove the dipstick and view the oil level. NOTE: The oil level reading will be accurate for only one to three minutes after turning off the engine. If the oil ch...

94 MAINTENANCE Engine Oil Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Clean the foam oil breather element with each engine oil change. See page 97.Always use the recommended oil. See page 91, or see your Polaris dealer about oil ...

96 MAINTENANCE Engine Oil Oil Change 22. Make sure the engine coolant temperature is between 145 and 160 degrees F. (63-71 degrees C). If necessary, start the engine and allow it to idle until the coolant temperature is within the specified range. 23. Remove the dipstick from the oil tank. Clean the...

A B 97 MAINTENANCE Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to protect sensors within the intake system from damage due to oil ingestion. Clean or replace the breather element at each engine oil change. Clean the element if the snowmobile has been tippe...

+ + L L L L 98 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 c...

A B 100 MAINTENANCE Lubrication n Gearcase Oil Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88.Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 133 for the part numbers of Polaris products.The dipstick (A) is ...

102 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. CAUTION Using non-recommended spark plugs can result in serious engine damage. A spark p...

+ 103 MAINTENANCE Intake Filters 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. Fuel Injectors All fuel injector service must be performed by an authorized Pol...

104 MAINTENANCE Alternator Belt Inspection Inspect the alternator belt condition and tension at the intervals outlined in the Periodic Maintenance Table beginning on page 88.1. Stop the engine.2. Open the hood.3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, inst...

105 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 88. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with...

A 106 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required.Use Premium 60/40 anti-freeze coolant, which is already prem...

107 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your snowmobile after the high temperature indicator light has co...

108 MAINTENANCE Cooling System Bleeding the Cooling System WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. 1. Read the entire coolant bleed procedure befor...

A B 110 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....

111 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 67.Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16 ″ (1.5mm). A kit is available for replacing brake pads...

112 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...

113 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...

B A C 114 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum covering fr...

115 MAINTENANCE Electrical System RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOID RELAY Ground side of start solenoid SPARE 20A None CHASSIS ACCESSORY EMERGENCY SPARE 30A Accessory plugs CHASSIS RELAY High beams RELAY CHASSIS Low beams CHASSIS 30A Handwarmers 30A ThumbwarmerTail lampBrake lampAlt...

A 116 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 pat...

A B 117 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 exi...

11:00 2:00 + 118 MAINTENANCE Clutch System Drive Belt Removal CAUTION 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. 1. Stop the engine after operating in a forward motion. N...

119 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 ...

+ 120 MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size recommended for your model. See your Polaris dealer. CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a t...

121 MAINTENANCE Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death.Avoid operating for extended periods on ice and oth...

122 MAINTENANCE Track Tension 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 adjustment is critical for pro...

123 MAINTENANCE Track Tension 4. Check for specified slack (C) between the wear surface of the track clip and the plastic rail slide. 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 t...

+ + 7/16 ″ (1.1 cm) 124 MAINTENANCE n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engin...

125 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 ″ 126 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...

+ 127 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...

128 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable ...

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

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

131 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 133 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with ...

132 MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model. CAUTION Fogging the engine improperly can result in damage to the sensors. Fogging is not recommended. Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring...

133 POLARIS PRODUCTS Part No. Description Engine Lubricants 2874865 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Gre...

134 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Possible Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 34. Jammed clutch Check for twisted belt or broken spring. See your dealer. Jammed track Remove any for...

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

136 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Possible Cause Solution Engine Management System RPM Reduction Mode is activated See causes on page 34. Low battery voltage Recharge the battery to 12.8 VDC. Water is present in fuel See your dea...

137 TROUBLESHOOTING Engine and Drive Train Troubleshooting Harsh Drive Clutch Engagement Possible Cause Solution Worn drive belt Replace with the recommended belt. Excessive belt/sheave clearance See your dealer. Drive Belt Turns Over Possible Cause Solution Incorrect belt Replace with the recommend...

140 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM S Drive at higher RPM. 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...

141 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...

142 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 ...

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

145 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...

146 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...

147 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 the new engine, including all parts of its emission- control system, is designed, ...

149 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)...

152 INDEX A Accessories 61 . . . . . . . . . . . . . . . . . . . . Adjustable Headlights 30 . . . . . . . . . . . . Air Filter 104 . . . . . . . . . . . . . . . . . . . . . Alternator Belt Inspection 104 . . . . . . . . Avalanches 16 . . . . . . . . . . . . . . . . . . . . B Battery 128-130 . . . . ...