Polaris 900 Fusion - Manual

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

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

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

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

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

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

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

11 SAFETY Operator Safety 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 20. WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts ...

12 SAFETY Operator Safety Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather....

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

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

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

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

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

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

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

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Eq...

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

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

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

24 SAFETY Safety Decals and Locations Operation Warning Operation Warning Decal: S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is missing, contact a Polaris dealer for a replacement. S This vehicle is capable of high speed...

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

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

1 28 FEATURES Seat Storage Compartment Open or close the storage compartments with the key. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left (to lower the beam) or to the right (to raise the beam). Access Panel The access panel (1) is provided for cleaning debris fr...

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

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

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

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

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

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

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

36 FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. “SErVCE” will fl...

37 FEATURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn’t working properly, replace the battery. Replacement batteries are available from your dealer.1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment (A). It has a red wire a...

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

1 2 4 3 3 5 39 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 c...

40 THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 110 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set ...

41 THE PERFECT FIT Front Suspension Adjustments IQ 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...

42 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving RydeFX 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 RydeFX shocks requires special tools and a sound knowledge of m...

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

X Y 44 THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the IQ rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.Take the first measurement with no rider and with the rear suspens...

2 1 3 45 THE PERFECT FIT IQ 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.1. Soft...

46 THE PERFECT FIT IQ 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 suspension coupling, these torque arms could move independently of each other. Rear suspensio...

47 THE PERFECT FIT IQ 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 independent movement between the rear torque and the front t...

2 1 H M L L 48 THE PERFECT FIT IQ 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 (1) is the best for most trail riding conditions.To decrea...

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

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

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

52 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm ...

53 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (1) increases ski pressure while the upper hole (2) decreases ski pressure. NOTE: By design, the BIASED COUPLE design of...

54 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 27. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster bloc...

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

56 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.Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from impro...

57 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...

59 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...

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

4 3 1 2 61 PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock Use the park brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.1. Brake Lever 2. Park Brake Lever Lock 3. Master Cylinder...

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

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

64 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 59. Do not d...

65 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...

66 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. Maintain the oil level at the bottom of the filler neck. See page 67. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of f...

67 OPERATION Oil n Low Oil Level The low oil indicator light will alert the operator if the oil level is low. Add oil before further operation of the snowmobile. See page 66 for oil recommendations. CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine dam...

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

69 OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in ...

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

73 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 71 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

74 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is ...

75 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 ″ (10 cm) off the ground.Remove the key and cover the machine. Towing WARNING Objects towed with a rope...

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

77 MAINTENANCE Emission Control Information Owner’s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 130, and read the maintenance section of your owner’s manual. You are responsible for ensuring that the specified maintenance is performed, including the emission...

78 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 132.The recommende...

79 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris d...

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

+ + 83 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lig...

1 2 3 84 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). C...

4 85 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely 3. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the...

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

2 87 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust syst...

1 88 MAINTENANCE Intake Filter The intake foam filter (1) limits snow ingestion into the intake system. When operating in loose powder snow, check the foam filter periodically to remove any accumulation of snow. Fuel Injectors All fuel injector service must be performed by an authorized Polaris deal...

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

90 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...

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

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

1 2 93 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. ...

94 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile.Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2 ″ (1.3 cm). Br...

95 MAINTENANCE Brakes Brake Components 1. Brake Caliper 2. Brake Disc 3. Backing Plate 4. Brake Pad Material (Replace when thick- ness is less than 1/16 ″ /1.5mm). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 94), bring the machi...

96 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...

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

2 1 3 98 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. Removing Halogen Bulbs 1. Remove the plenum covering fro...

99 MAINTENANCE Lights Taillight/Brakelight Replacement 1. Open the rear storage compartment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. 5. Replace th...

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

A 101 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist...

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

A B 1 .010 ″ -.030 ″ (.25-.75mm) 103 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”...

104 MAINTENANCE Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician wil...

A 105 MAINTENANCE Track Maintenance 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 re...

A 106 MAINTENANCE Track Maintenance n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the machine with the track off the ground. 2. Start the engine a...

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

108 MAINTENANCE Track Maintenance Track Tension 4. Check for specified slack (1) between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 107. I f the track needs adjustment: 5. Loosen the rear idler shaft bolt (2).6. Loosen the locknuts (3). 7...

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

X Y 10 ″ 10 ″ 110 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straig...

1 111 MAINTENANCE Steering System n Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death.See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the ori...

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

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

114 MAINTENANCE 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 117 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with ...

115 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch co...

116 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained dur...

117 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Go...

118 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during Drive clutch binding S SEE YOUR DEALER. RPM during acceleration or ...

121 TROUBLESHOOTING IQ Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspensionbottoms too easily S Adjust torsion spring preload to achieve proper static sag (see page 44). S Change torsion spring to stiffer optional spring (see your dealer). S Revalve rear tr...

122 TROUBLESHOOTING M-10 Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily S Increase FRA position (see page 50). S Install appropriate optional center retainer on rear track shock (see page 51). S Increase front track shock coil sprin...

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

124 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...

125 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 ...

127 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...

128 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...

129 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...

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

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

134 INDEX A Access Panel 28 . . . . . . . . . . . . . . . . . . . Accessories 55 . . . . . . . . . . . . . . . . . . . . Adjustable Headlights 28 . . . . . . . . . . . . Avalanches 14 . . . . . . . . . . . . . . . . . . . . B Bearings 115 . . . . . . . . . . . . . . . . . . . . . Before Starting the...