Polaris PMS 419 - Manual

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

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

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

9 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 77 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT d...

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

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

12 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab-lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label....

13 SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only. WARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or...

14 SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information. WARNING! Overloading the cargo carrier can cause loss of control resulting in severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg). Never exceed the cargo carrier capacity. Disabled Operators...

15 SAFETY Operator Safety 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. Always observe all state and local laws governing snowmobile opera-tion and speed limits. Always be ...

16 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...

17 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 be...

18 SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, 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 ...

19 SAFETY Operator Safety Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and seri...

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

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will result in ...

22 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. ...

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

24 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 ...

25 SAFETY Safety Decals and Locations Passenger Warning Snowmobiles designed for an operator and one passenger have a warn-ing decal on the console. For more information on operating with a pas-senger, see page 13. WARNING This vehicle is designed for operator and “ONE” passenger only. Track Warning...

26 SAFETY Safety Decals and Locations Reverse Warning POLARIS snowmobiles equipped with standard reverse and will have this decal on the console: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look be...

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

28 FEATURES 3 4 5 6 12 2 1 9 10 11 17 13 14 15 16 19 18 21 7 8 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield 7. Mountain Bar 8. Handlebar 9. Seat 10. Backrest 11. Taillights12. Cargo Carrier13. Rear Bumper14. Snow Flap15. Track16. Suspension17. Grab Handle Heater Switch18. Ba...

30 FEATURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for-ward for operator use or rear-ward for passenger use. 3. Always tighten the knobs s...

31 FEATURES Adjustable Headlights Move the headlight adjuster to raise or lower the headlight beam. • Move the adjuster to the left to lower the beam. • Move the adjuster to the right to raise the beam. Shifter For normal operation, place the transmission in high gear. When-ever towing or operating ...

33 FEATURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con-troller to select the proper operating software based on the type of fuel being used. See pages 64-65 for fuel information and recommendations. The ECU fuel designation connector must have the “NON-ETHANO...

34 FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate, flicker or flash momentarily.. Yo...

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

36 FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref-erences. The rocker switch has a MODE button (top) and a SET but-ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or...

37 FEATURES Instrumentation MFD Settings Speedometer/Tachometer If your model is equipped with both analog and digital displays, the speedometer and tachometer can be viewed in either display. If the ana-log display is set to show speedometer readings, the digital screen will automatically display t...

38 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro-grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycl...

40 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4. When the hour starts flashing, press ...

41 FEATURES Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri-cal system voltage level, fuel level (if equipped) and either engine cool-ant temper...

42 FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. Tip: Press and hold the MODE switch for...

43 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the M...

44 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that serv...

45 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds...

46 FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replace-ment batteries are available from your dealer. 1. Remove the plenum from the under- side...

47 FEATURES Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the battery holder. Pull the battery out gently. Tip: The battery will not come out of the holder unless the leading edge of the b...

48 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 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 cond...

49 THE PERFECT FIT Rear Suspension Adjustments Rider weight, cargo weight, riding style, trail conditions and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However, all suspen-...

50 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the dis-tance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at f...

51 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This adjustment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of ad...

52 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style. High : Limiter strap in high position increases ski pressu...

53 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving The rear track shocks for this model are gas charged shocks. The valv-ing on the gas charged shocks is pre-set.

54 THE PERFECT FIT Handlebar Adjustments Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar. 2. Remove the handlebar cover. 3. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block. Turn the handlebar to the left or right...

55 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 snowmo-bile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry re...

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

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

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 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 leve...

60 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmo-bile to remain stationary; for exam-ple, when parked on an incline for a period of five minutes or less. Lock Engagement To engage the lock, squeeze the brake ...

61 PRE-RIDE INSPECTIONS Before Starting the Engine n Track Inspection WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicl...

62 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 ...

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 Lightin...

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

65 OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethano...

66 OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel as outlined below. Oil added to the fuel and oil injection systems will ...

67 OPERATION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds...

68 OPERATION Starting the Engine 1. Turn the key to the ON position. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 2. Pull the engine stop switch up to t...

69 OPERATION Restarting an Engine If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2. Turn the key to the OFF...

70 OPERATION n Oil Low Oil Indicator Light The low oil indicator light may flicker at times due to oil movement in the bottle, but when the light comes on and remains on, add the recom-mended oil before further operation. Visually check the oil level in the bottle. The engine may be operated as long...

71 OPERATION Track Warm-Up A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle dur-ing warm-up or when the track ...

72 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 RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is remove...

73 OPERATION n Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine speed limits at 2400 RPM when th...

74 OPERATION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or trans-mission if shifting is attempted when the engine is operating above idle speed. • Shift to or from rev...

75 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and sup-port 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 snowmobile. Towing For your safety, do not a...

76 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) la...

77 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 131. The recomme...

78 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...

81 MAINTENANCE Lubrication n Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 77. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. To check the oil level, place the snowmobi...

82 MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the han-dlebars to the left and lubri-cate liberally as shown. Front Suspension The front suspension and steering components do not require lubrica-tion. Coupler Lubrication U...

83 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium All Sea-son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 78 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 mil...

84 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. NOTICE: Using non-recommended spark plugs can result in serious engine damage. A spark p...

85 MAINTENANCE Spark Plugs Normal Spark 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. Tip: The tip should not be white. A white ...

86 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause intake icing. The...

87 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km). Have your dealer inspect the return check valve as wel...

88 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premix...

89 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool-ant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indi-cator light has come...

90 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly...

91 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. Brake pads must be replaced when the brake pad material becomes thin-ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail-able for replacing brak...

92 MAINTENANCE Brakes n Brake Fluid 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 drop, whi...

93 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...

94 MAINTENANCE Lights Removing Halogen Bulbs Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi-due, 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. 1. Remove the plenum cov- ering from th...

95 MAINTENANCE Lights Installing Halogen Bulbs 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness. 5. Reinstall the ...

96 MAINTENANCE Electrical System RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOIDRELAY Ground side of start solenoid CHASSISRELAY SPARE 20A None ACCESSORYEMERGENCYSPARE 30A Accessory plugs CHASSIS30A High beams Low beams Handwarmers Thumbwarmer Passenger handwarmers Work light Tail lamp Brake lamp...

97 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...

98 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. S...

99 MAINTENANCE Clutch System Drive Belt Adjustment 1. Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 100). Turn the wrench clockwise slightly to remove pressure from the sheaves. 2. Loosen the 7/16-inch jam nut. 3. Using a 1/8-inch Allen wrench, aturn th...

100 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure f...

101 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the brea...

102 MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size rec-ommended for your model. See your POLARIS dealer. NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a tr...

103 MAINTENANCE Track Lubrication WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and o...

104 MAINTENANCE Track Tension 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 adjustment is critical for pr...

105 MAINTENANCE Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal...

106 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 snowmobile with the track off the ground. 2. Start the engine and apply a small...

107 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.     

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

109 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...

110 MAINTENANCE Battery WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable...

111 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

112 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less u...

113 MAINTENANCE Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping dirt, oils and other contami-nants. POLARIS Industries recommends cleaning with warm water and a mild dish detergent. Use a soft sponge to gently rub the surface and rinse with clean warm water. For s...

114 MAINTENANCE Extended Storage Battery Maintenance Remove the battery and recharge it as outlined on page 112. Store the battery in a cool, dry place. Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 78. Bearings G...

115 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...

116 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) (break-in only) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) (break-in only) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l) 2877953 VES Go...

117 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 • SEE YOUR DEALER. Dri...

120 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Set static sag (see page 50). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. Rides too stiff in rear • Check for binding suspension components and...

121 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. 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 weather and warm it up. Break machine loose ...

122 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty infor-mation contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates o...

123 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...

124 WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED 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 pa...

126 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 vehi-cle Pre-Delivery Inspection, perform all applicable service bulletins and have the co...

127 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 expo...

128 WARRANTY How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name ...

131 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 km...

134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 55 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches. . . . . . . . . . . . . . . . . . . . 17 B Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery . . . ....