Polaris 2005 440 IQ- User Manual

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

7 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...

8 INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers in the spaces provided. Vehicle Model Number: Tunnel VIN: (lower right side of the tunnel) Engine Serial Number: (right front side of engine crankcase)

9 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...

10 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 63 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....

11 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...

12 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...

13 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your Polari...

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: 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...

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

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

18 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...

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

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

21 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.WIND CHILL CHART ( ° F) Estimated Wind Speed in MPH Actual Thermometer Reading ( ° F) Speed in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60...

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

23 SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: Passenger Warning This snowmobile is designed for one operator only. A “No Passenger” warning decal is located on the console: + +

24 SAFETY Safety Decals and Locations Operation Warning +

26 FEATURES AND CONTROLS 1. Brake Lever 2. Tachometer 3. Temperature Light 4. Engine Stop Switch 5. Throttle Control 6. Choke Control 7. Recoil Starter Handle 8. Fuel Filler Cap 9. Park Brake Lock 10. Headlight Dimmer Switch 11. Handlebar Grip Warmer/ Thumbwarmer Switch 12. Tether Switch 13. Master ...

28 FEATURES AND CONTROLS Polaris DRAGON Ignition System Your snowmobile is equipped with an ignition system feature that improves competition performance by increasing exhaust system temperature. The DRAGON Ignition System provides maximum “holeshot” performance for racing applications. WARNING DRAG...

29 FEATURES AND CONTROLS Polaris DRAGON Ignition System DRAGON Mode Operation 1. Warm up the engine and track. See page 56. 2. When staged at the starting line, depress and hold the DRAGON (horn) button on the left handlebar (1). 3. Slowly advance the throttle to the wide-open position while keeping...

1 3 2 4 30 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail condi...

1 31 THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 96 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set...

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

33 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on Walker/Evans shocks requires special tools and a sound kn...

34 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...

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

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

37 THE PERFECT FIT IQ Rear Suspension Adjustments Clicker Shock Turn the clicker knob (1) on the shock reservoir to adjust compression damping.Turn the knob toward the “H” to increase damping (for a stiffer ride). Turn the knob toward the “S” to decrease damping (for a softer ride).When adjusting, w...

38 THE PERFECT FIT IQ Rear Suspension Adjustments Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that cont...

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

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

41 THE PERFECT FIT Handlebar Adjustments Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/4” Allen wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment req...

42 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories.Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may resul...

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

44 THE PERFECT FIT Accessories CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8 ″ (2.86 c...

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

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

48 PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic Brakes 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 ″ (1.3 cm). A smaller distance indicates low bra...

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

50 PRE-RIDE INSPECTIONS Before Starting the Engine n Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable c...

51 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine. n Tether Switch: Make sure the engine shuts off when the tether is removed from the sw...

52 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 3.5 gallons (13.2 l) of gasoline with 16 oz. (473 ml) of the recommended 2-cycle racing oil (28:1). Premix future gasoline at ...

53 OPERATION Fuel Recommendations 110 Octane The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Always use 110 octane fuel for the 440 IQ snowmobile. If the appropriate head kit has been installed, 92 octane may be used, but always adjust the t...

54 OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not overfill the tank. Do not fill the tank neck. S Do...

55 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 47. Starting...

56 OPERATION WARNING A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track i...

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

58 OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.A lea...

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

60 OPERATION n Engine Stop Switch Push down on the engine stop switch (1) to stop the engine in an emergency. To restart the engine, pull the switch up to the ON position. Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 60 ...

61 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. WARNING Serious injury can result from wrapping the start strap around your hand while using the...

62 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. Cover the machine with an appropriate cover. Towing WARNING Objects towed wit...

63 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual. Record services performed in the Maintenance Record at the rear of this manual.The recommended mainte...

64 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...

67 MAINTENANCE Lubrication Lack of lubrication will adversely affect your ride and the life of components. Lubricate 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. A grease gun kit, complete with...

68 MAINTENANCE Lubrication Front Suspension Only two components of the IQ front suspension and steering require lubrication. S Grease the left and right spindles. Raise the front end of the ma- chine to permit better grease entry into the spindle area. S Grease the upper steering post.

69 MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Pus...

70 MAINTENANCE Lubrication n Chaincase Oil Level It’s the operator’s responsibility to check and maintain the proper chaincase oil level.To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris synthetic chaincase...

71 MAINTENANCE Spark Plugs 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 production, a manufacturer assumes that the engine will be operated unde...

72 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system...

73 MAINTENANCE Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters removed may cause carburet...

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

75 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. CAUTION Operating the snowmobi...

76 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...

77 MAINTENANCE Engine Cooling Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34 ° F (-37 ° C). If greater protection is required, the percentage of antifreeze to water...

78 MAINTENANCE Engine Cooling Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done wh...

79 MAINTENANCE Engine Cooling Bleeding the Cooling System 3. Tip the snowmobile slightly onto its right side. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow, but not enough to engage the clutch. This allows air to bleed from the rear crossover tube. NOTE: There must be enough co...

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

81 MAINTENANCE n Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Squeeze the brake lever. It should move no closer to the handgrip than 1/2 ″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on...

82 MAINTENANCE Brakes Brake Components 1. Brake Caliper 2. Chaincase 3. Brake Disc 4. Backing Plate 5. Brake Pad Material (Replace when thickness is less than 1/16 ″ ). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on pa...

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

84 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 ...

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

86 MAINTENANCE Headlights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring ret...

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

88 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile....

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

90 MAINTENANCE Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010 ″ to a maximum of .030 ″ from the engine case (2). Adjust if necessary, and loc...

91 MAINTENANCE Chain Tension Maintain the proper chain tension as outlined on page 80. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Tool Kit A tool...

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

93 MAINTENANCE Track Maintenance I f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start the machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply b...

94 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. Using a hoist, sa...

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

96 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 positi...

A 97 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 orig...

A 7/16 ″ (1.1 cm) 98 MAINTENANCE Suspension Maintenance n Slider Wear Measure slider thickness at several points along the rail. Have your dealer replace the slider when it’s worn down to the top of the wear groove (A). Do not operate the snowmobile if slider thickness measures less than 7/16 ″ (1.1...

99 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 pla...

100 MAINTENANCE Extended Storage Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days,the engine must be fogged wit...

101 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 103 for the part numbers of Polaris products.Replace worn or frayed electrical...

102 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported:1. Turn the fuel valve clockwise to OFF to shut off the fuel supply (1). Turn the valve counter-clockwise to ON to turn the fuel supply on (2). NOTE: The fuel valve is located under the hood. 2. Be sure the fuel cap i...

103 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2873023 Synthetic 2-Cycle Racing Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grease / Specialized Lubricants 2871312 Grease ...

104 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engineoperating RPMduring accelera-tion or loadvariations Drive clutch binding Driven clutchmal...

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

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

109 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...

110 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 ...

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

113 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...

114 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 ex...

115 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km)

118 INDEX A Accessories 42-45 . . . . . . . . . . . . . . . . . . Avalanches 15 . . . . . . . . . . . . . . . . . . . . B Bearings 99 . . . . . . . . . . . . . . . . . . . . . . Before Starting the Engine 47-50 . . . . . . Belt Troubleshooting 108 . . . . . . . . . . . Bleeding the Cooling System 67...