Polaris 500 XC SP - Manual

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage governments to adopt rigorous safety training pro- grams that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other o...

6 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...

7 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 74 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. DO NOT dr...

8 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the igni- tion, raise the hood, make the adjustment, secure shields and...

9 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards ...

10 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...

11 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...

12 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...

13 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...

14 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, remove ice and snow build-up that may be obstructing the steering linkage. Driving...

15 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...

16 SAFETY Operator Safety Driving in Hilly Terrain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and avoid po...

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

18 SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20 _ F), Polaris recommends cl...

19 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....

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

21 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...

22 SAFETY Safety Decals and Locations Track Warning The track 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. "No Passenger" Warning Some snowmobiles ar...

23 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models have a reverse warning decal on the lower dash.: WARNINGReverse operation, even at low speeds, can cause loss of con- trol resulting in serious injury or death. To avoid loss of con...

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

26 FEATURES Some Polaris snowmobiles are equipped with special features such as a reverse indicator light, electronic fuel gauge, temperature light and elec- tric shock control gauge. Not all models come with these features. Refer to your Owner's Manual Supplement for the features on your machine. 1...

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

29 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. To determine if your machine is using full travel, push the jounce bumper down on the shock ro...

30 THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiff- ness of Indy Select shocks can be made by turning the adjustment screw located near the base of the shock ( + ). This adjustment is the easiest to per- form and it should be considered first. A clockw...

31 THE PERFECT FIT Front Suspension Adjustments 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 adjustme...

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

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

34 THE PERFECT FIT EDGE Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspen- sion torsion spring preload, mea- sure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear su...

35 THE PERFECT FIT EDGE Rear Suspension Adjustments 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. See your dealer for more information. Soft Tensi...

36 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjust- ment screw located near the base of the shock. Locate the adjustment sc...

37 THE PERFECT FIT EDGE Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other. Rear suspe...

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

39 THE PERFECT FIT EDGE Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding condi- tions. To decrease weight t...

40 THE PERFECT FIT Handlebar Adjustments Handlebar Angle Follow these steps to adjust handlebar angle at the handle- bar block.1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16 I (11 mm) wrench, loosen the four nuts (3) on the bottom of ...

41 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in:• Non-compliance with government/industry requ...

42 THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer ...

43 THE PERFECT FIT Traction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle...

44 THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed. Wear strips are designed ...

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

46 PRE-RIDE INSPECTIONS Before Starting the Engine Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience. n Throttle Lever The throttle and brake are the primary controls of your snowmo...

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

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

49 PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Lock Release To release the lock, squeeze the brake lever tightly and release it. The lock will return to the unlock position. WARNING If the parking brake lever lock is partially or entirely engaged while riding, the brakes...

50 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System 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, remove ice and snow build-up that may be obstructing the stee...

51 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure...

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

53 OPERATION Starting the Engine 1. Turn the fuel valve on. See page 57. 2. Turn the key to the ON position.3. Pull the engine stop switch up to the RUN position. 4. If starting a cold engine, flip the choke toggle to FULL ON. Do not use the choke if starting a warm engine. NOTE: Do not depress the ...

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

55 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 60. Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems. On Polaris snowmobiles equipped with a variable exhaust sys- tem (VES), Polaris highly ...

57 OPERATION Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. Fuel WARNING Gasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline. ...

58 OPERATION Fuel 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 across the country, so we encourage the use of premium fuel when possible. Always use the...

59 OPERATION Fuel Fuel Reserve Capacity (Mechanical Gauge) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to t...

60 OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. n Low Oil Level Maintaining the proper oil level will prevent system aeration and possi- b...

61 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 le...

62 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. The carbu...

65 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

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

67 OPERATION Reverse Operation Mechanical Reverse Make sure the shift lever is shifted completely into forward or reverse position. Some models are equipped with a reverse indicator light that will help you make that determination. Do not force the shift lever into reverse if resistance is felt. The...

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

69 OPERATION Reverse Operation Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off. 3. Appl...

70 OPERATION Daily Storage At the end of each ride, park the snow- mobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. Remove the key and cover the machine.

71 OPERATION Towing For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions. If the snowmobile becomes inoperable and must be towed, and if it isn't possible to use a rigid tow bar, attach the tow rope to the ski spindles ...

72 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...

73 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 140, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is per- formed, including the emissi...

74 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 142. The recom...

75 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...

78 MAINTENANCE Lubrication Suspension and Steering 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. A grease gun kit, complete with grease and adaptors, is available to lubricate all...

79 MAINTENANCE Lubrication EDGE Rear Suspension + + + + +

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

81 MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease. Before turning the engine o...

82 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the mainte- nance charts beginning on page 74. 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 “safe”...

83 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your ...

84 MAINTENANCE Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insu...

85 MAINTENANCE Intake Filters The intake foam filter ( + ) limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tan...

86 MAINTENANCE Oil Filter The oil filter should be changed annually or every 1000 miles (1600 km). Inspect oil line condition at 1000 miles (1600 km). Polaris oil filters are specially designed for use on Polaris products. We strongly recom- mend the use of only Polaris replacement parts. See page 5...

87 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 at least every 2000 miles (3200 km) and inspected for contami...

88 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. Carburetor Adjustments The fre...

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

90 MAINTENANCE Cooling System The cooling system on liquid cooled models consists of the following major components: • Coolant bottle• Water pump• Cylinders• Heads• Inlet and outlet manifolds• Pressure cap• Heat exchangers

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

92 MAINTENANCE Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are:• Coolant bottle or overflow tank• Engine filler neck• Pressure cap (on some models)• Connecting hoses Always maintain the coolant level between the minimum...

93 MAINTENANCE Cooling System Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. Perform the bleeding procedure when the engine is cold.1. Remove the ...

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

95 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 47. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 I ). A kit is available for replacing brake pads. Se...

96 MAINTENANCE Brakes Brake Fluid On some models, the brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. On all other models, frequently chec...

97 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. During the bleeding procedure, keep the brake handle as level as possi- ble. The reservoir must be in this position to m...

98 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...

99 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Bulb Removal 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer. 2. Lift the s...

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

101 MAINTENANCE Clutch System Clutch Alignment Offset Clutch center distance and align- ment ( + ) are crucial to maintain- ing optimum performance. See your Owner's Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed. Belt width and length must m...

102 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. ...

103 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion.2. Turn the ignition key off. Wait for the engine to stop completely.3. Lock the parking brake (if equipped).4. Open the hood. 5. Remove the clutch guard retain- ing pin and open the clutch guard....

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

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

106 MAINTENANCE Clutch System Torque Stop If your snowmobile is equipped with an engine torque stop, periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010 I -.030 I (.25-.75 mm) from the engine case. Adjust if necessary, and lock the ja...

107 MAINTENANCE Chain Tension Maintain the proper chain tension as outlined on page 94. 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 too...

108 MAINTENANCE Track Track Inspection 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track along the entire length of each rod ( + ). Bend the track to check for breakage. 4. Replace th...

109 MAINTENANCE Track Track Lubrication The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear. NOTE: If excessive rail slide wear occurs due to poor snow condit...

110 MAINTENANCE Track Track Tension Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment. NOTE: Tension adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off.2. Lift the rear of the machine and safely support it o...

111 MAINTENANCE Track Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt.6. Loosen the locknuts. 7. Tighten or loosen the track adjusting screws to provide equal adjust- ment on both sides of the track. 8. Repeat the measurement on the other side of the track. NOTE: Che...

112 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...

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

114 MAINTENANCE Steering System Ski Alignment With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. The measurement between the skis at point X should be 1/8 I to 1/4 I ...

115 MAINTENANCE Steering System n Ski Skags Check skags before each use of the snowmobile to ensure positive steer- ing characteristics. Skags must be replaced when worn to half their orig- inal diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chip- ping is found. Skag Replacem...

116 MAINTENANCE Steering System 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. Failure to do...

117 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 125 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts wit...

118 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Lubricate the sheave faces...

119 MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the fol- lowing procedure1. Transfer unused fuel from the fuel tank to an approved fuel con-...

120 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. Replace worn or frayed electrical wire and connectors. Be sure wiring harness is proper...

121 MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with th...

122 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...

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

124 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more:• Remove the battery.• Charge it to the proper level.• Store it in a cool dry place.• Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging. Batt...

125 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...

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

129 TROUBLESHOOTING EDGE Suspension Troubleshooting Problem Solution Rear suspension bot- toms too easily • Increase torsion spring preload• Increase rear shock compression damping by turning screw clockwise • Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear • Check fo...

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

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

132 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...

133 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 ...

135 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...

136 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 ...

137 WARRANTY Polaris Second Year Engine Service Contract Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion. Coverage is automatic with no addi- tional paperwork required. The free Second Year Engine Serv...

138 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...

139 WARRANTY Exported Vehicles How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs...

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

142 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...

144 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 41 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Airbox Warning . . . . . . . . . . . . . . . . 21 Avalanches. . . . . . . . . . . . . . . . . . . . 13 B Battery . . . . . . . . . . . . . . . . . . . 121-123 Battery Connections. ....