Page 4 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.• Snowmobiles• All-terrain vehicles (ATVs)• RANGER utility vehicles • Victory motorcyclesWe believe Polaris sets a s...
Page 6 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety . . . . . . . . . . . . ....
Page 7 - INTRODUCTION; Important Notes for Owners and Drivers; snowmobile before allowing them to make longer trips. Teach them
4 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold.When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sur...
Page 8 - Preservation of the Environment; Noise Level; One of the most publicized issues about snowmobiles is noise. The; Air Pollution
5 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...
Page 9 - Vehicle Identification Numbers
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...
Page 10 - SAFETY; Operator Safety; CAUTION; NOTICE
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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal in...
Page 11 - WARNING
8 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 60 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...
Page 12 - Stay Clear of Track; exposed for proper operation.; Stay Clear of Engine; Never
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...
Page 13 - Survival Preparation
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...
Page 14 - Riding Apparel; Helmet
11 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 established safety standards.Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.Ap...
Page 15 - Cargo Overload; Rider Capacity
12 SAFETY Operator Safety Cargo Overload Too much weight on the rear of the snowmobile may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Disabled Operators Safe operation of this rider-active veh...
Page 16 - Excessive Speed
13 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. Observe all state and local laws governing snowmobile operation. They’ve been established for your p...
Page 17 - Driver Awareness
14 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...
Page 18 - Avalanches
15 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...
Page 19 - Ice and Snow Build-up; your dealer to help reduce snow and ice build-up.; Driving on Slippery Surfaces
16 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 ...
Page 20 - Driving on Slopes; unavoidable, keep your weight low and forward. If you must cross the
17 SAFETY Operator Safety Driving on Slopes WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain...
Page 21 - Driving Downhill; snowmobile and keep it from rolling freely downhill.; Clutch Guard; Do not operate the engine with the clutch guard removed.; remote, don’t defeat the purpose of the guard by removing it. It’s pro-; Drive Belt; Do not operate the engine with the drive belt removed.
18 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely do...
Page 22 - Intake Silencer; Clutches; Do not attempt to service the clutches.; All clutch service must be performed by your dealer. The clutch is a; Cold Weather Drive-Away; Whenever your snowmobile has been parked for a length of time, espe-; Maneuverability; ing system and skis, maximum control is achieved by the shifting of
19 SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed. NOTICE: Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. T...
Page 23 - Inadequate Snow Conditions; and, on liquid cooled models, cooling for the engine, adequate snow; Operating in Deep Snow; of snow, then step down the snow in front of the snowmobile so that
20 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. WARNING! Inadequate cooling and lubrication will l...
Page 24 - Driving Responsibly
21 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 snowmobile and with what it will and won’t do under various conditio...
Page 25 - Windchill/Temperature Charts; peratures become dangerous for riding.
22 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 ...
Page 26 - Safety Labels and Locations; on the snowmobile; Clutch Cover Warning; Air Box Warning; under the hood; Passenger Warning
23 SAFETY Safety Labels and Locations Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always r...
Page 27 - The track/seat warning label is on the; Reverse Warning; Polaris Widetrak snowmobile is
24 SAFETY Safety Labels and Locations Track/Seat Warning The track/seat warning label is on the rear of the tunnel: WARNINGStay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Polaris Widetrak snowmob...
Page 28 - Operation Warning
25 SAFETY Safety Labels and Locations Operation Warning An operation warning label is present on the console of all Polaris snow- mobiles: 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 d...
Page 29 - FEATURES AND CONTROLS
26 FEATURES AND CONTROLS 1. Fuel Filler Cap (may include a fuel gauge)2. Ignition Switch3. Brake Lever4. Speedometer (may include indicator/warning lights)5. Reverse Indicator6. Mountain Bar7. Engine Stop Switch (see page 54)8. Throttle Control9. Choke10. Recoil Starter Handle 5 4 3 2 1 10 9 7 8 6 G...
Page 30 - Not all; Fuel Valve
27 FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement. 1. Headlight Dimmer Switch2. Parking Brake Lock3. Handlebar Grip Warmer Sw...
Page 32 - Backrest; Cargo Rack
29 FEATURES AND CONTROLS Backrest The backrest is adjustable for either operator or pas- senger 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 rearward for pas- senger use. 3. Always ti...
Page 33 - THE PERFECT FIT; Front Suspension Adjustments; Break in the suspension for approximately 150 miles (240 km) and re-; IFS Components
30 THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re- grease all suspension parts before making any fine-tuning adjustments.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditi...
Page 34 - the jounce bumper down as far as it will go on the shock rod and test; Shock Components
31 THE PERFECT FIT Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page 92 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 is called spr...
Page 35 - Shock Spring Preload
32 THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski- to-ground pressure. Front Springs For models without exter- nally adjustable or revalv- able shocks, the front springs can...
Page 36 - Rear Suspension Adjustments; Suspension Performance Tips
33 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 condi- tions. However, all suspension design...
Page 37 - WideTrak Rear Suspension Adjustments; Rear Spring Settings; check for the recommended settings:
34 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 snowmobile to relieve the rear springs.2. Slowly lower the snowmobile and measure the distance...
Page 38 - Handlebar Adjustments; Standard Handlebar
35 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the mountain bar by removing nuts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right ...
Page 39 - Traction Products; Carbide Skags; control on hard-packed snow and ice. Replace worn skags to maintain
36 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. Inspect skags frequently. Worn skags may reduce steering and braking ...
Page 40 - Accessories; must
37 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.Use only Polaris parts and accessories on your Polaris ...
Page 41 - ) on the referenced pages to; Item
38 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...
Page 42 - Before Starting the Engine; vehicle components to be sure of proper operation.; Read and Understand Your Owner’s Manual; Read the Owner’s Manual completely and refer to it often. The manual; Throttle Lever; the engine. Have the throttle serviced immediately. See page 55.; Throttle Safety Switch
39 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 ...
Page 43 - Hydraulic Brakes; Brake Lever Travel; Squeeze the brake lever. It should; Lever Feel; your dealer for service.
40 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 inch (1.3 cm). A smaller distance indicates low brake ...
Page 44 - Parking Brake Lever Lock; Lock Engagement; Lock Release
41 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five...
Page 45 - Steering System; ficulty is encountered, check for ice and snow build-up that may be; Track; cation conditions voids the track warranty.
42 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left. If any dif- ficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubri...
Page 46 - Hood Latches; found, see your Polaris dealer for replacement.; Transmission; Make sure the transmission is
43 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...
Page 47 - Start the Engine and Check; Engine Stop Switch; OFF
44 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 Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned ou...
Page 48 - OPERATION; Starting the Engine; CHOKE POSITIONS
45 OPERATION Starting the Engine 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. 1. Turn the fuel valve on. See page 27. 2. Turn the key to the ON position...
Page 49 - mobile life as proper break-in of a new or rebuilt engine. Premix the
46 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free snow- mobile life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubricati...
Page 50 - Oil Injection System; Always check and fill the oil tank when refueling. See page 50.; Oil Recommendations; systems. Polaris recommends the use of Premium 2-Cycle Oil for this; Slide Rail and Track Cooling
47 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 50. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your deale...
Page 52 - Fuel; Fuel Safety
49 OPERATION Fuel Fuel Safety Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.• Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not overfill the tank. Do not fill the tank neck.• ...
Page 53 - use of premium fuel when possible. Do not use lower than 87 octane; mechanical fuel gauge reads; Fuel System Deicers; Never use deicers or additives containing
50 OPERATION Fuel Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible. Do not use lower than 87 octane f...
Page 54 - Oil; Low Oil Indicator Light
51 OPERATION n Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 47 for oil recommendations.When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may...
Page 55 - Low Oil Level; reaches the low level mark, add one U.S. quart of recommended oil to; Carburetion; be caused by snow build-up on the pre-filter in the air intake system.
52 OPERATION n Oil Low Oil Level Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 47 for oil recommendations.The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See y...
Page 56 - Jetting Guidelines; production is not correct for all altitudes and/or temperatures.
53 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.RMK carbur...
Page 59 - Emergency Stopping; engine stop switch and throttle safety switch.; Emergency Starting; gency start strap is provided in the kit.; SYSTEM
56 OPERATION n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 54 for more information about the engine stop switch and throttle safety switch. Emergency Starting Your snowmobile is equipped with a tool kit containing essen...
Page 60 - Reverse Operation; Mechanical Reverse; should be made by your dealer.
57 OPERATION Reverse Operation 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 attempted when the engine is operating above idle speed. • Shift to or from rever...
Page 61 - Towing; Do not use the front bumper to pull or drag the snowmobile. The front; (not to the ski loops) to prevent damage to the steering components.
58 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the...
Page 62 - MAINTENANCE; Emission Control Information; Emission Control Label; tion hangtag. These items are required by U.S. Environmental; Emission Control Maintenance Requirements; any service that may be necessary.
59 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) l...
Page 63 - Polaris Recommended Maintenance Program; lined in this manual. Record maintenance and service in the Mainte-
60 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 118.The recomm...
Page 64 - Periodic Maintenance Interval Table; may need to increase frequency based on riding conditions. When
61 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...
Page 67 - Lubrication; Suspension and Steering; mium All-Season Grease at 500 miles (800 km) and annually or every
64 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...
Page 69 - Jackshaft Bearing
66 MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor ...
Page 70 - Gearcase Oil Level; fill
67 MAINTENANCE Lubrication n Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 63. 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 snow- mob...
Page 71 - Spark Plugs; engine under medium or light duty to have spark plug failure.; Owner’s Manual Supplement.
68 MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your snowmobile. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.In selecting a spark plug heat range for p...
Page 72 - spark plug for correct color.; Normal Plug; end. There may be a carbon layer over the entire nose. Generally, the; Spark Plug Removal and Replacement; spark plug counterclockwise to remove it.
69 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. CAUTION! A hot exhaust syste...
Page 73 - Intake Filter; system. When operating in loose powder snow, check the top of the
70 MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters remo...
Page 74 - Carburetor; Water/Sediment Trap Service; Plug Cleaning Procedure
71 MAINTENANCE Carburetor Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contaminat...
Page 75 - Carburetor Adjustments
72 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. NOTICE: Operating the snowmobi...
Page 76 - Fuel Filter/Fuel Lines; damaged fuel lines promptly.; Oil Filter; The oil filter is located at the side of
73 MAINTENANCE Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance.Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel...
Page 77 - Exhaust System; Check the exhaust system for wear or damage at approximately 1000; Drive Chain Tension; tenance or inspection should be necessary.
74 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or da...
Page 78 - Brakes; Hydraulic Brake Inspection; available for replacing brake pads. See your dealer.; Brake Components; ness is less than 1/16
75 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 40.Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16 inch (1.5 mm). A kit is available for replacing brake...
Page 79 - Brake Fluid; allow for diaphragm movement, and if they become plugged, movement; Replace brake fluid at least every two years.
76 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 dr...
Page 80 - Bleeding the Hydraulic Brake System; Bleed the system before operating the snowmobile.; flow of fluid into an approved container.
77 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...
Page 81 - Lights; Headlight Adjustment; and make a mark on the wall.; Turn the adjustment nut, located inside the hood, just below the
78 MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure:1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight a...
Page 82 - Headlight Bulb Replacement
79 MAINTENANCE Lights Avoid touching 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 fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Replacement 1. Pinch the ends of the spring (1) t...
Page 83 - Clutch System; ers such as isopropyl alcohol.; Clutch Alignment Offset; for your machine. If adjustment is necessary, see your dealer.
80 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt resi- due. To maintain optimum performance, clean with non-oil based clean- ers such as isopropyl alcohol. NOTICE: If you become aware of higher than normal clutch engagement or an unusual vibration or shi...
Page 84 - Drive Belt Condition; any of these conditions exist.
81 MAINTENANCE Clutch System n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shif...
Page 85 - Drive Belt Removal; Stop the engine after operating in
82 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. 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 compo- nents during belt removal. 2. Turn the i...
Page 86 - Drive Belt Installation
83 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: 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 re...
Page 87 - Drive Belt Deflection
84 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 (1) and apply downward pres- sure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). Drive Belt Adjus...
Page 88 - Tool Kit; Always keep the tool kit with the snowmobile.; Chain Tension; Maintain the proper chain tension as outlined on page 74.
85 MAINTENANCE Tool Kit A tool kit is included with each snowmobile for emergency and routine maintenance. Always keep the tool kit with the snowmobile. Chain Tension Maintain the proper chain tension as outlined on page 74. Fall Tune-Up For maximum performance, arrange for a fall service tune-up wi...
Page 89 - Track Inspection
86 MAINTENANCE Track 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 rear of the snow...
Page 90 - Track Lubrication
87 MAINTENANCE Track 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 ...
Page 91 - Track Tension; after the track is warmed up and limber.; and the plastic rail slide.
88 MAINTENANCE Track 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 run- ning. Track Tension Track adjustment is critical for prop...
Page 92 - f the track needs adjustment:; equal adjustment on both sides of the track.
89 MAINTENANCE Track Track Tension I f the track needs adjustment: 6. Loosen the rear idler shaft bolt.7. Loosen the locknuts.8. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track. 9. Repeat the measurement on the other side of the track....
Page 93 - Track Alignment; slowly
90 MAINTENANCE Track n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a s...
Page 94 - Steering Inspection; sary. Specific fasteners that should be checked are marked with a
91 MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary. Specific fasteners that should be checked are marked with a + in the illustration. + + + + + +
Page 95 - Ski Alignment; With the handlebars in a straight-ahead position, and with vehicle
92 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 posit...
Page 96 - Ski Skags; trol while turning on hard-packed snow or ice.; skags must be replaced if; Skag Replacement; Raise and support the front of the snowmobile so the skis are
93 MAINTENANCE Steering System n Ski Skags See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle con- trol while turning on hard-packed snow or...
Page 97 - Suspension Maintenance; Rail Slide Wear
94 MAINTENANCE Suspension Maintenance n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure...
Page 98 - Battery; Battery Fluid; A poorly maintained battery will
95 MAINTENANCE Battery Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi- cal attention.KEEP OUT OF REACH OF CHILDREN.EXTERNAL: Flush with water.INTERNAL: Drink large quantities of water ...
Page 99 - Battery Connections; and one cup water. Rinse well with tap water and dry with clean shop; Battery Removal; ways or spill electrolyte.
96 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessary, remove the corrosion with a stiff wire brush. Wash ter- minals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water...
Page 100 - Battery Installation; kinks and to allow for proper drainage.
97 MAINTENANCE Battery Battery Installation WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. 1...
Page 101 - Battery Storage; When your snowmobile is placed in storage for one month or more (in; Charge condition
98 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter):• Remove the battery.• Charge it to the proper level.• Store it in a cool dry place.• Check and/or charge monthly.• Have the battery tested and recharged before reinstallin...
Page 102 - Daily Storage
99 MAINTENANCE 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 inches (10 cm) off the ground.Remove the key and cover the snowmobile. Tip: Polaris has accessory c...
Page 103 - Extended Storage; Cleaning and Preservation; Proper storage starts with cleaning, washing, and waxing the hood,; Engine and Carburetor Protection; Whenever the snowmobile is stored for a period of more than 60 days,
100 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and pl...
Page 105 - Electrical Connections; Always prepare and maintain the battery as outlined on page 95.; Track and Suspension; Remove the ignition key to prevent loss.
102 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 103 for the part numbers of Polaris products.Replace worn or frayed electrical...
Page 106 - POLARIS PRODUCTS; Description
103 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...
Page 107 - TROUBLESHOOTING; Suspension Troubleshooting; Problem
104 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bot- toms too easily • Verify sag dimension (see page 89). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. Rear suspension rides too...
Page 108 - Belt Wear/Burn Troubleshooting; Belt Wear/Burn Diagnosis
105 TROUBLESHOOTING Belt Wear/Burn 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 snowmobile in extremely cold wea...
Page 109 - Engine Troubleshooting; your dealer if technical problems arise.
106 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 operating RPM during acceler- ation or load variations Drive clutch binding • Disassemble drive c...
Page 112 - WARRANTY; Service And Warranty Information; Obtaining Service and Warranty Assistance; following information:; Polaris Customer Service
109 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warranty. Your dealer receives frequent update...
Page 113 - Polaris Anti-Theft System; Polaris snowmobile owner reports theft.; list of all stolen units to further monitor thefts.
110 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...
Page 114 - Limited Warranty; Limitations of warranties and remedies
111 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 ...
Page 116 - Conditions and Exclusions
113 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...
Page 117 - Polaris Second Year Engine Service Contract; Consumer Exclusions
114 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 ...
Page 118 - Exported Vehicles; How to Get Service; Notice
115 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...
Page 121 - MAINTENANCE LOG; mobile is serviced. This will provide you and future owners with an
118 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...
Page 125 - INDEX
122 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 37 Air Box Warning . . . . . . . . . . . . . . . 23 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Apparel . . . . . . . . . . . . . . . . . . . . . . 11 Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Backrest . . . . . . ....