Polaris Indy 340 Touring - 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 programs that encourage protection of our environment, including wild- life 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 80 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 par- tially 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 a...

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. Cargo Overload Too much we...

12 SAFETY Excessive Speed Always observe all laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per sec- ond your machine travels. If your speed is 40 MPH, your machine i...

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:• 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...

15 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 diffi- culty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. Drivi...

16 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...

17 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...

18 SAFETY Operator Safety Clutch Guard Do not operate the engine with the clutch guard removed. The clutch guard is designed to protect the operator from metal parts if the clutch should fail. Although the chance of failure is extremely remote, don't defeat the purpose of the safety guard by removin...

19 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...

20 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....

21 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...

22 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 man- ual differ from the decals on your snowmobile, alwa...

23 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 can result in severe injury or death. Passenger Warning Polaris touring models and the WideTrak...

24 SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snow- mobile is equipped with stan- dard reverse. The reverse warning decal is located above the instrument housing: WARNINGReverse operation, even at low speeds, can cause loss of control resulting in serious injury...

25 SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse 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- ...

26 SAFETY Safety Decals and Locations Operation Warning The operation warning decal is located on the console: • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a Polaris dealer for a replacement. • This vehi...

27 FEATURES Some Polaris snowmobiles are equipped with special features. Operat- ing controls and special feature controls are illustrated on this page. Not all models come with all special features. See your Owner's Manual Supplement. 1. Fuel Filler Cap 2. Ignition Switch 3. Accessory Plug 4. Brake...

30 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 ...

31 THE PERFECT FIT Front Suspension Adjustments 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 rod until it contacts the body and te...

33 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...

34 THE PERFECT FIT 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. Front Springs For models without externally adjustable or revalvable shocks, the front springs can b...

35 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...

36 THE PERFECT FIT Rear Suspension Adjustmments 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 ar...

37 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Initial Spring Preload Setting (Sag Method) To set up the EDGE 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 a...

38 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Rear 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 inf...

39 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. Locate the adjust- ment screw near the base of the shock. In half-turn increments,...

40 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) 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 ...

41 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Suspension Coupling 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 m...

42 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) 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- tion...

43 THE PERFECT FIT EDGE Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if fre- quent bottoming is encou...

44 THE PERFECT FIT EDGE Touring Suspension (ETS) Adjustments The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 43)...

45 THE PERFECT FIT EDGE Touring Suspension (ETS) Adjustments Front Arm Mounting Holes There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole increases ski pressure while the upper hole decreases ski pressure. Increasepressure Decreasepressure

46 THE PERFECT FIT WideTrak Rear Suspension Adjustments Rear Spring Settings Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs.2. Slowly lower the machine and measure the distance betwe...

47 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...

48 THE PERFECT FIT Passenger Grab Handle Adjustment On some Touring models the position of the passenger grab handles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab handles. 2. Reposition the grab handles to one of the three available positions o...

49 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...

50 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 ...

51 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...

52 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 ...

53 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...

54 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...

55 PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic 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 distance indicates low brake flu...

56 PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock If your model is equipped with the park brake lever lock, use the 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. Park Br...

57 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 diffi- culty is encountered, remove ice and snow build-up that may be obstructing the st...

58 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...

59 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 ...

60 OPERATION Starting the Engine 1. Turn the fuel valve on. See page 64.2. 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 t...

61 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...

62 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 67. 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 ...

64 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.•...

65 OPERATION Fuel Your Polaris engine is designed to run on 87 octane non-oxygen- ated 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 t...

66 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...

67 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...

68 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...

69 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...

70 OPERATION n Engine Stop Switch Push down on the engine stop switch ( ✪ ) 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 r...

71 OPERATION Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. Turn the ignition switch to OFF.2. Visually inspect the throttle cable and carburetor to determine what caused the safety switch to activate. 3. Test the throttle lever by compressing and releasing it se...

72 OPERATION Passenger Seat The passenger seat features an adjustable lumbar support. To adjust for rider com- fort, rotate the lumbar adjustment knob. The passenger seat and trunk cover are removable. Removing the cover and seat will provide open storage for transporting larger items. 1. Remove the...

73 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...

74 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...

75 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 on page 76. Always make sure the vehicle is stopped and the engin...

76 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...

77 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. Towing For your safety, do not attemp...

78 MAINTENANCE Emission Control Information (340cc and 600cc Engines Only) Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag. These items are required by U.S. Environmental...

79 MAINTENANCE Emission Control Information (340cc and 600cc Engines Only) Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 150, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is pe...

80 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 152. The recom...

81 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...

84 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...

85 MAINTENANCE Lubrication EDGE 136 Rear Suspension (Indy 340 Touring) Edge Touring Rear Suspension ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪

86 MAINTENANCE Lubrication WideTrak Rear Suspensions ✪ ✪ ✪ ✪ ✪

87 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...

88 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...

89 MAINTENANCE Lubrication n Gearcase Oil Level (WideTrak) Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 80. Change the gear- case oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. To check the oil level, place...

90 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the mainte- nance charts beginning on page 80. 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”...

91 MAINTENANCE General 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...

92 MAINTENANCE General Maintenance Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be whi...

93 MAINTENANCE General 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. NOTE: These illustrations are general representations. Y...

94 MAINTENANCE General Maintenance Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- ...

95 MAINTENANCE General 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...

96 MAINTENANCE General Maintenance 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 fo...

97 MAINTENANCE General 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 ret...

98 MAINTENANCE General Maintenance Cooling System (Liquid Cooled Models) 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 Coolant Use Premium 60/40 anti-fre...

99 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on...

100 MAINTENANCE General Maintenance 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. Recovery System (WideTrak) If the coolant level becomes low in ...

101 MAINTENANCE General Maintenance Bleeding the Cooling System Surge Tank Models Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark. 2. Elevate the front end of the machine slightly to aid in...

102 MAINTENANCE General 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 br...

103 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 55. 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 ...

104 MAINTENANCE General Maintenance 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, f...

105 MAINTENANCE General Maintenance 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...

106 MAINTENANCE General Maintenance 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 ...

107 MAINTENANCE General Maintenance 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. Headlight Bulb Replacement High/Low Beam Style ...

108 MAINTENANCE General Maintenance Taillight/Brakelight Replacement 1. Remove the rear storage cover (1) if equipped.2. Depending on your model, remove the screws (2) securing either the taillight housing (3) or the lens cover (4). 3. Remove and replace the bulb (5).4. Reassemble all components. 1 ...

109 MAINTENANCE General 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 vibr...

110 MAINTENANCE General Maintenance 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 ...

111 MAINTENANCE General Maintenance 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 e...

112 MAINTENANCE General Maintenance 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 ...

113 MAINTENANCE General Maintenance 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 t...

114 MAINTENANCE General Maintenance 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 A...

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

116 MAINTENANCE General Maintenance Chain Tension Maintain the proper chain tension as outlined on page 102. 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 cond...

117 MAINTENANCE Track Maintenance 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...

118 MAINTENANCE Track Maintenance 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 ...

119 MAINTENANCE Track Maintenance Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 118. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock- nuts. 7. Tighten ...

120 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 and...

121 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. ✪ ✪ ✪ ✪ ✪ ✪ ✪ WideTrak ✪ ✪ ✪ ✪ ✪ ✪ EDGE IFS

122 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 ...

123 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...

124 MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at sev- eral points along the rail. Have your dealer replace the slide when it's worn down to the mini- mum thickness. Do not operate the snowmobile if slide thickness measures less. 7/16 I (1.1 cm) 3/8 I (1 cm) Minimum Thickn...

125 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 follow- ing items on a weekly basis or before ...

126 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 134 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts wit...

127 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. To prevent oxi- dation on ...

129 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...

130 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. Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessar...

131 MAINTENANCE Battery Battery Removal 1. Disconnect battery hold down straps.2. Remove battery vent tube from battery.3. Disconnect black (negative) battery cable first.4. Disconnect red (positive) battery cable second.5. Carefully lift the battery out of the snowmobile. Do not tip it side- ways o...

132 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...

133 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 recharg- ing. Ba...

134 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...

135 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...

140 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...

141 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, ser- vice or warranty. Your dealer receives frequent update...

142 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...

143 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 ...

145 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...

146 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 ...

147 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...

148 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...

149 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, War- ranty or Service Bulletin repai...

150 WARRANTY Snowmobile Engine Emissions Limited Warranty (340cc and 600cc Engines Only) 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 emission...

152 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...

154 INDEX A Accessories . . . . . . . . . . . . . . . . . . 49 Air Pollution . . . . . . . . . . . . . . . . . . 5 Airbox Warning . . . . . . . . . . . . . . . 22 Avalanches. . . . . . . . . . . . . . . . . . . 14 B Battery . . . . . . . . . . . . . . . . . . 130-133 Battery Connections. . . . . . ....