Polaris Trail RMK - Manuals

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and...

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

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

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alco...

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

11 SAFETY Operator Safety 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 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 Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Disabled Operators Safe operation of this rider-active vehicl...

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

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

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

17 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. Operating in hilly terrain requires extreme ...

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

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

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 machine. NOTICE: Driving in too little snow will result in exc...

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

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

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

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

25 SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, con- tact a Polaris dea...

26 FEATURES AND CONTROLS 1. Fuel Filler Cap (may include a fuel gauge)2. Ignition Switch3. Brake Lever4. Speedometer (may include indicator/warning lights)5. Reverse Indicator6. Mountain Bar (accessory)7. Engine Stop Switch (see page 58)8. Throttle Control9. Choke10. Recoil Starter Handle 5 4 3 2 1 ...

27 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. See your Owner’s Manual Supplement. Tip: Accessories are available from your Polaris dealer. 1. Headlight Dimmer Sw...

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

30 THE PERFECT FIT Front Suspension Adjustments WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Always verify ski alignment before making adjustments to the IFS. See page 98 to check alignment. Do not attempt to change the ski a...

31 THE PERFECT FIT Front Suspension Adjustments Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more...

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

33 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 condi- tions. However, all suspension design...

34 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, mea- sure the distance between the ground and rear bumper (see illustration). This measurement should be taken with no rider and the rear suspensi...

35 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method)) To determine sag, commonly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration for re...

36 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.The following in...

37 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Damping Your snowmobile is equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. 1. Locate the adjustment screw near the base of the shock.2. Adjust the screw 1/2 turn clockwise to increase ...

38 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster blo...

39 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.Use only Polaris parts and accessories on your Polaris ...

40 THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTICE: Installing studs ...

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

43 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items Item See Pa...

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

45 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 i...

46 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five ...

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

48 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 Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned ou...

49 OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the fuel valve on. See page 27. 2. Turn the key to the ON position...

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

51 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 55. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your de...

53 OPERATION Slide Rail and Track Cooling NOTICE: 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...

54 OPERATION Fuel Fuel Recommendations Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible. Do not use l...

55 OPERATION n Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. If oil is not visible, continued opera- tion may cause serious engine damage. Add oil before further operation of the snowmobile. See page 51 ...

56 OPERATION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments.A lean mixture (too much air, too little fuel) may result in piston burn- ing, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little ...

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

58 OPERATION n Engine Stop Switch Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. n Throttle Safety Switch The throttle safety switc...

60 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 58 for more information about the engine stop switch and throttle safety switch. WARNING! Excessive or repetitive use of brakes for high speed stops will cause an...

61 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 62. Always make sure the vehicle is stopped and the engine is running at id...

62 OPERATION Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is ru...

63 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the...

64 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) l...

65 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 124.The recomm...

66 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...

70 MAINTENANCE Lubrication Front Suspension Lubricate the suspension and steering components with Polaris Pre- mium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 109 for the part numbers of Polaris products.The illustration shows the location...

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

72 MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor ...

73 MAINTENANCE Lubrication n Chaincase Oil Level Check the chaincase oil level at the intervals outlined in the mainte- nance charts beginning on page 66. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or season- ally.Maintain the oil level between the “...

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

75 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. CAUTION! A hot exhaust syste...

76 MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters remo...

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

78 MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobi...

79 MAINTENANCE Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance.Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel...

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

81 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 45.Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is available for replacing brake ...

82 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...

83 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...

84 MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure:1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight a...

85 MAINTENANCE Lights NOTICE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Removing Halogen Bulbs 1. Pinch the ends of the spring (...

86 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt resi- due. To maintain optimum performance, clean with non-oil based clean- ers such as isopropyl alcohol. NOTICE: If you become aware of higher than normal clutch engagement or an unusual vibration or shi...

87 MAINTENANCE Clutch System n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shif...

88 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 2. Turn the ign...

89 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: 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 re...

90 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 (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). Drive Belt Adjustm...

91 MAINTENANCE Clutch System Torque Stop Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010-.030 inch (.25-.75 mm) from the engine case.Adjust if necessary, and lock the jam nut. Tool Kit A tool kit is included with each machine for ...

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

93 MAINTENANCE Track 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 ...

94 MAINTENANCE Track 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 run-ning. Track Tension Track adjustment is critical for prope...

95 MAINTENANCE Track Track TensionI f the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts.8. Tighten or loosen the track adjusting screws as necessary to pro- vide equal adjustment on both sides of the track. 9. Repeat the measure- ment on the other side of the tr...

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

97 MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary. Specific fasteners that should be checked are marked with a + in the illustration. + + + + + +

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

99 MAINTENANCE Steering System n Ski Skags See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle con- trol while turning on hard-packed snow or...

100 MAINTENANCE Suspension Maintenance n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failur...

101 MAINTENANCE Battery Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi- cal attention.KEEP OUT OF REACH OF CHILDREN.EXTERNAL: Flush with water.INTERNAL: Drink large quantities of water...

102 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessary, remove the corrosion with a stiff wire brush. Wash ter- minals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap wate...

103 MAINTENANCE Battery Battery Installation WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. ...

104 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter):• Remove the battery.• Charge it to the proper level.• Store it in a cool dry place.• Check and/or charge monthly.• Have the battery tested and recharged before reinstalli...

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

106 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and pl...

108 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 109 for the part numbers of Polaris products.Replace worn or frayed electrical...

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 SUSPENSION TROUBLESHOOTING Problem Solution (perform only one change at a time) Rear suspension bot- toms too easily • Verify sag dimension (see page 34). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. • Increase shock compression damping (see...

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

112 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 acceler- ation or load variations Drive clutch binding • Disassembl...

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

116 WARRANTY Service And Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

117 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective ...

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

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

121 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for e...

124 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 k...

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 39Air Box Warning . . . . . . . . . . . . . . . 23 Air Pollution . . . . . . . . . . . . . . . . . . . 6Apparel . . . . . . . . . . . . . . . . . . . . . . 12Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . ....

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and...

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

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

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alco...

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

11 SAFETY Operator Safety 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 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 Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Disabled Operators Safe operation of this rider-active vehicl...

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

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

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

17 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. Operating in hilly terrain requires extreme ...

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

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

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 machine. NOTICE: Driving in too little snow will result in exc...

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

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

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

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

25 SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, con- tact a Polaris dea...

26 FEATURES AND CONTROLS 1. Fuel Filler Cap (may include a fuel gauge)2. Ignition Switch3. Brake Lever4. Speedometer (may include indicator/warning lights)5. Reverse Indicator6. Mountain Bar (accessory)7. Engine Stop Switch (see page 58)8. Throttle Control9. Choke10. Recoil Starter Handle 5 4 3 2 1 ...

27 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. See your Owner’s Manual Supplement. Tip: Accessories are available from your Polaris dealer. 1. Headlight Dimmer Sw...

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

30 THE PERFECT FIT Front Suspension Adjustments WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Always verify ski alignment before making adjustments to the IFS. See page 98 to check alignment. Do not attempt to change the ski a...

31 THE PERFECT FIT Front Suspension Adjustments Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more...

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

33 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 condi- tions. However, all suspension design...

34 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, mea- sure the distance between the ground and rear bumper (see illustration). This measurement should be taken with no rider and the rear suspensi...

35 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method)) To determine sag, commonly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration for re...

36 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.The following in...

37 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Damping Your snowmobile is equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. 1. Locate the adjustment screw near the base of the shock.2. Adjust the screw 1/2 turn clockwise to increase ...

38 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster blo...

39 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.Use only Polaris parts and accessories on your Polaris ...

40 THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTICE: Installing studs ...

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

43 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items Item See Pa...

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

45 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 i...

46 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five ...

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

48 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 Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned ou...

49 OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the fuel valve on. See page 27. 2. Turn the key to the ON position...

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

51 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 55. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your de...

53 OPERATION Slide Rail and Track Cooling NOTICE: 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...

54 OPERATION Fuel Fuel Recommendations Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible. Do not use l...

55 OPERATION n Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. If oil is not visible, continued opera- tion may cause serious engine damage. Add oil before further operation of the snowmobile. See page 51 ...

56 OPERATION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments.A lean mixture (too much air, too little fuel) may result in piston burn- ing, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little ...

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

58 OPERATION n Engine Stop Switch Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. n Throttle Safety Switch The throttle safety switc...

60 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 58 for more information about the engine stop switch and throttle safety switch. WARNING! Excessive or repetitive use of brakes for high speed stops will cause an...

61 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 62. Always make sure the vehicle is stopped and the engine is running at id...

62 OPERATION Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is ru...

63 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the...

64 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) l...

65 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 124.The recomm...

66 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...

70 MAINTENANCE Lubrication Front Suspension Lubricate the suspension and steering components with Polaris Pre- mium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 109 for the part numbers of Polaris products.The illustration shows the location...

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

72 MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor ...

73 MAINTENANCE Lubrication n Chaincase Oil Level Check the chaincase oil level at the intervals outlined in the mainte- nance charts beginning on page 66. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or season- ally.Maintain the oil level between the “...

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

75 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. CAUTION! A hot exhaust syste...

76 MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters remo...

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

78 MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobi...

79 MAINTENANCE Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance.Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel...

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

81 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 45.Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is available for replacing brake ...

82 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...

83 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...

84 MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure:1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight a...

85 MAINTENANCE Lights NOTICE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Removing Halogen Bulbs 1. Pinch the ends of the spring (...

86 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt resi- due. To maintain optimum performance, clean with non-oil based clean- ers such as isopropyl alcohol. NOTICE: If you become aware of higher than normal clutch engagement or an unusual vibration or shi...

87 MAINTENANCE Clutch System n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shif...

88 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 2. Turn the ign...

89 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: 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 re...

90 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 (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). Drive Belt Adjustm...

91 MAINTENANCE Clutch System Torque Stop Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010-.030 inch (.25-.75 mm) from the engine case.Adjust if necessary, and lock the jam nut. Tool Kit A tool kit is included with each machine for ...

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

93 MAINTENANCE Track 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 ...

94 MAINTENANCE Track 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 run-ning. Track Tension Track adjustment is critical for prope...

95 MAINTENANCE Track Track TensionI f the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts.8. Tighten or loosen the track adjusting screws as necessary to pro- vide equal adjustment on both sides of the track. 9. Repeat the measure- ment on the other side of the tr...

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

97 MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary. Specific fasteners that should be checked are marked with a + in the illustration. + + + + + +

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

99 MAINTENANCE Steering System n Ski Skags See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle con- trol while turning on hard-packed snow or...

100 MAINTENANCE Suspension Maintenance n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failur...

101 MAINTENANCE Battery Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi- cal attention.KEEP OUT OF REACH OF CHILDREN.EXTERNAL: Flush with water.INTERNAL: Drink large quantities of water...

102 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessary, remove the corrosion with a stiff wire brush. Wash ter- minals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap wate...

103 MAINTENANCE Battery Battery Installation WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. ...

104 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter):• Remove the battery.• Charge it to the proper level.• Store it in a cool dry place.• Check and/or charge monthly.• Have the battery tested and recharged before reinstalli...

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

106 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and pl...

108 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 109 for the part numbers of Polaris products.Replace worn or frayed electrical...

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 SUSPENSION TROUBLESHOOTING Problem Solution (perform only one change at a time) Rear suspension bot- toms too easily • Verify sag dimension (see page 34). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. • Increase shock compression damping (see...

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

112 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 acceler- ation or load variations Drive clutch binding • Disassembl...

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

116 WARRANTY Service And Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

117 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective ...

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

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

121 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for e...

124 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 k...

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 39Air Box Warning . . . . . . . . . . . . . . . 23 Air Pollution . . . . . . . . . . . . . . . . . . . 6Apparel . . . . . . . . . . . . . . . . . . . . . . 12Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . ....