Polaris 2002 User Manual

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Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

What’s the hottest thing on snow?

Our new web site. It’s designed just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

-NOTES-

WELCOME

Thank you for purchasing a Polaris snowmobile, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.

We believe Polaris sets the standard of excellence for all snowmobiles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris snowmobile the finest machine we’ve ever produced.

Follow t he instructions and recommendations in this Owner’s Manual for safe and enjoyable operation of your vehicle. Your Owner ’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

Your Polaris snowmobile dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

TABLE OF CONTENTS

Section 1 - How to Use This Manual 5 - 9.......

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner’s Manual.

Section 2 - Safety 1 1 - 34.....................

This section describes safe vehicle operation and identifies warning decals and their locations.

Section 3 - Features and Controls 36 - 41......

This section illustrates the locations of your snowmobile’s controls and features.

Section 4 - The Perfect Fit 43 - 63..............

This section explains how to tailor the suspension and other features for an optimum riding experience.

Section 5 - Getting Ready to Ride 65 - 71.......

This section explains procedures that must be performed before riding.

Section 6 - Operation 73 - 93..................

This section explains proper engine break-in, operation of features, and operating procedures.

Section 7 - Maintenance 95 - 155..............

This section defines your role, and your dealer ’s role, in your snowmobile’s regular maintenance.

Section 8 - Troubleshooting 157 - 166..........

This section is a quick reference guide to solving problems.

Section 9 - Warranty 170 - 175.................

This section contains specific warranty information.

SECTION 1 - HOW TO USE THIS MANUAL

Important Notes for Drivers 6.................

Preservation Of The Environment 7 - 8........

Vehicle Identification Numbers 9..............

Section 1 contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner’s Manual. It also defines your role in protecting and respecting your environment while experiencing The Way Out.

HOW TO USE THIS MANUAL

Important Notes For Owners And Drivers

n After reading this manual, store i t in the snowmobile for

convenient reference. It should remain with the snowmobile when sold.

n This manual contains the latest information at the time of printing.

We reserve the right to make product changes and improvements without notice.

n The illustrations and photos used in this manual are general

representations. Your model may differ.

n Follow the maintenance program outlined in this manual.

Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

n You and your dealer must complete the registration form included

with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

n Protect and preserve your right to ride by joining your local trail

riding clubs.

HOW TO USE THIS MANUAL

Preservation Of The Environment

Please operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.

In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.

HOW TO USE THIS MANUAL

Preservation Of The Environment

Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs t hat encourage protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and do your part to preserve and protect our environment.

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

HOW TO USE THIS MANUAL

Vehicle Identification Numbers

Please record your snowmobile identification numbers below for future reference:

Tunnel VIN (lower right side of the tunnel)

Engine Serial Number (right front side of engine crankcase)

Remove the spare key and store it in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and mating it with your existing key.

The VIN and engine serial numbers are necessary for model identification when registering your vehicle and obtaining insurance, or when replacement parts are required. If your snowmobile is stolen, these numbers are essential to its recovery and identification.

Dealer Imprint

-NOTES-

SECTION 2 - SAFETY

Operator Safety 12 - 27.......................

Safety Decals and Locations 28 - 34...........

Section 2 describes safe vehicle operation and identifies warning decals and their locations.

SAFETY

Operator Safety

The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your snowmobile or in this manual, alerts you to the potential for personal injury.

WARNING

Indicates a potential hazard that could result in serious injury or death.

CAUTION

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

CAUTION

Indicates a situation that may result in damage to the machine.

NOTE

“NOTE:” will alert you to important information or instructions.

IMPORTANT

“IMPORTANT:” will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

Polaris produces high performance snowmobiles capable of traveling at high speeds. Extra caution must be observed to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. We strongly recommend that the operator check major and vital safety components before every ride.

All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile.

SAFETY

Operator Safety

Stay Away From Moving Parts

WARNING

Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.

We recommend having your dealer perform track service and alignment procedures.

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

WARNING

Stop the engine before attempting adjustments. If contact is made with fingers or clothing, the moving parts of an engine can cause serious injury.

Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.

SAFETY

Operator Safety

Be Seated and in Position to Control the Vehicle

WARNING

Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle.

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably positioned for proper throttle, brake, and steering control.

WARNING

Use of a backrest may hinder your weight shifting ability . This could affect your ability to control this rider-active vehicle in certain extreme driving situations.

Be Prepared for the Unexpected

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 that’s appropriate to the conditions you may encounter. Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular t elephone.

SAFETY

Operator Safety

Do Not Overload Cargo Carrier

Too m uch weight on the rear of the machine 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.

WARNING

Control becomes more difficult with two people on board. More space is required to make turns, and longer distances are needed for stopping. Make sure the passenger remains seated behind the driver, facing forward, with both feet placed firmly on the running boards. Slow down and avoid “jumping” your snowmobile.

Always Wear Clo thing Designed for Snowmobiling

WARNING

Loose clothing or long scarves may easily become entangled in moving parts and cause serious personal injury.

Always wear an approved helmet and eye protection.

Be aware of the weather forecast and especially the wind chill. A table is provided on page 26 for your reference. To better enjoy your ride, be prepared, warm, and comfortable.

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.

Know the Limitations of the Machine and Your Skills as a Driver

WARNING

High speed driving, especially at night, is dangerous and unwise and could result in serious personal injury or death.

Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.

Always be alert and pay attention to the trail ahead of you. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH, your machine will travel about 180 feet in two seconds.

Traveling at night requires extra caution. Check headlight and taillight to ensure proper operation, and don’t “over drive” your headlight beam. Always be able to bring your machine to a stop in the distance illuminated by the headlight.

SAFETY

Operator Safety

Know the Limitations of the Machine and Your Skills as a Driver

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 wires on utility poles are also difficult to distinguish.

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your machine will drown out the sound of approaching vehicles. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you. Before riding your machine on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. You may drown if you and the snowmobile break through the ice.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Snow screens and bib kits are available through your dealer to help reduce snow and ice build-up.

Operation on Hard-Packed Snow or Slippery Surfaces

WARNING

Driving on ice or hard-packed snow reduces steering and braking control, which may result in serious injury or death. Slow down and use caution.

Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions.

It’s dangerous to drive on ice or other slippery surfaces. If it’s unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction. The chance of “spin-out” increases under these conditions.

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all 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 possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops, or other people or vehicles that may be on the other side of the hill.

If you’re unable to continue up a hill, turn the machine downhill before it loses m omentum. If this isn’t possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the parking brake (if equipped). Keeping away from the downhill side of the machine, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the machine, restart the engine, release the parking brake, and descend the hill carefully.

SAFETY

Operator Safety

Riding 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.

WARNING

When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

Do Not Operate Engine With 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 guard by removing it. It’s provided for your safety.

Do Not Operate Engine With Drive Belt Removed

Any servicing that requires operation without a belt must be performed by your dealer. Operation of t he engine with the belt removed may result in personal injury or damage to the engine.

SAFETY

Operator Safety

Do Not Operate Engine With Intake Silencer or Filter Removed

Damage to the engine may occur if the intake silencer or filter are removed.

Do Not Service Clut ch es Yourself

All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the machine into motion, but always operate within safety limits and, on 2-Up machines, with respect for a passenger. See page 74 for more detailed instructions on cold weather drive-away.

Machine M an eu verability

Control and maneuverability comes not only through the steering and skis, maximum control i s achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to carry a load or a passenger.

SAFETY

Operator Safety

Powder Snow Operation

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 closing t he upper hood closure.

WARNING

Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious personal injury.

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 machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

If the machine becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the machine so that when the throttle is opened, the snowmobile will be able to climb up and over. You may then mount the machine and continue riding.

CAUTION

When operating on icy surfaces or hard-packed snow, avoid overheating the slide rail and track. Lack of lubrication and cooling will cause overheating of the slide rail and track, resulting in premature wear and failure. If frequently operating in low cooling conditions, see your dealer for an optional wheel kit that will reduce the wear from overheating.

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 96 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. See page 30 for decal location.

Driving 2-Up - Some Polaris snowmobiles are designed for two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. See page 30 for decal location.

Machines designed for two riders should never be operated with more than two people on board. When traveling with a passenger, it’s the driver’s responsibility to operate the machine safely.

Slow down! Control becomes more difficult with two people on board. More space is required to make turns, and longer distances are necessary for stopping.

SAFETY

Operator Safety

Responsible Driving

Every snowmobile handles differently, and even the m ost docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.

n A snowmobile depends on the rider’s body position for proper

balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

n Before allowing someone else use your snowmobile, know the

extent of their operating skills. Check to see i f they’ve taken a snowmobile safety course and have an operator’s certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

n Don’t “jump” your snowmobile. Jumping may injure your back

because of spinal compression. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

n Be courteous to oncoming traffic by dimming your headlights and

reducing your speed. Your snowmobile is equipped with a high output headlamp system that may cause discomfort to operators of oncoming vehicles when on high beam.

n When traveling in a group of snowmobiles, don’t tailgate (follow

too closely). Allow ample stopping distances, and keep track of those following you. Drive defensively to avoid accidents.

n Don’t tempt anyone to steal your snowmobile or ride it without

permission. Remove the key from the ignition.

SAFETY

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Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when temperatures become dangerous for riding.

WIND CHILL CHART (°F)

Estimated Wind S peed

50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

Calm 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

5 48 37 27 16 6 -5 -15 -26 -36 -47 -57 -68

10 40 28 16 4 -9 -21 -33 -46 -58 -70 -83 -95

15 36 22 9 -5 -18 -36 -45 -58 -72 -85 -99 -11

20 32 18 4 -10 -25 -39 -53 -67 -82 -96 -110-12

25 30 16 0 -15 -29 -44 -59 -74 -88 -104-118-13

30 28 13 -2 -18 -33 -48 -63 -79 -94 -109-125-14

35 27 11 -4 -20 -35 -49 -67 -82 -98 -113-129-14

40 26 10 -6 -21 -37 -53 -69 -85 -100-116-132-14

Wind Speeds Greater

Than 40 MPH Have

Eff

Little Danger

(For Properly

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

Operator Safety

inKPH

)

WIND CHILL CHART (°C)

SAFETY

Estimated Wind S peed

0 5 0 -5 -10 -15 -20 -25 -30 -35 -40

10 1 -4 -11 -16 -22 -27 -33 -38 -45 -50

20 -4 -9 -17 -23 -29 -36 -42 -48 -54 -61

30 -7 -13 -21 -28 -35 -42 -48 -55 -63 -69

40 -9 -16 -24 -32 -39 -47 -53 -61 -69 -76

50 -11 -18 -26 -34 -41 -49 -57 -64 -73 -80

60 -12 -19 -27 -35 -43 -51 -59 -66 -75 -82

70 -13 -20 -28 -36 -44 -52 -60 -68 -76 -84

Wind Speeds Greater

Than 70 KPH Have Little

dded E

ect

Actual Thermometer Reading (°C)

5 0 -5 -10 -15 -20 -25 -30 -35 -40

Equivalent Temperature (°C)

Little Danger

(For Properly

lothed Person

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

SAFETY

Safety Decals And Locations

NOTE: Wa rning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed on the decal.

Clutch Cover Warning Decal - 1

This warning decal is found under the hood on the clutch cover:

Do not operate engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with this guard open.

Never run engine with drive belt removed.

Never service clutches yourself - see your dealer.

Airbox Warning Decal - 2

This warning decal is found under the hood on specific models:

Do not operate above 40 mph with hood-to-airbox foam removed or engine failure will result.

Pressure Cap Warning Decal - 3

This warning decal is found under the hood near the pressure cap of specific liquid cooled models:

Release pressure before removing cap. Cooling fluid must be up to the base of the pressure cap in hot or cold conditions.

Refer to the Owner’s Manual for fluid level in overflow bottle.

1, 2, 3

SAFETY

Safety Decals And Locations

Track Warning Decal - 4

The track warning decal is on the rear of the tunnel (4):

Stay clear of track.

Do not sit on seat back or cargo area.

Combined cargo and tongue weight should not exceed 40 lbs. (18 kg). Cargo load affects machine steering response.

Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

Cargo Carrier Warning Decal - 5

Machines with a cargo carrier will have this warning decal on the rear rack or on the taillight:

Do not sit in or on cargo area.

Cargo load should not exceed 40 lbs. (18 kg).

Cargo load affects machine steering and response.

Never allow person(s) to use carrier as a means of hand support, (skiing, skidding or dragging).

Severe injury may result due to track entanglement, falling off, or loss of steering control if warnings are not followed.

SAFETY

Safety Decals And Locations

Passenger Warning - 5

Some snowmobiles are designed for the operator only, while others are designed for the operator and one passenger. A warning decal on either the console or the hood of your machine indicates whether it’s designed for the operator only (1-Up) or the operator and a passenger (2-Up). For more information on operating capacities, see page 24.

Decal text found on 1-Up Models:

This vehicle is designed for operator only. “NO PASSENGER”

Decal text found on 2-Up Models:

This vehicle is designed for operator and “ONE” passenger only.

SAFETY

Safety Decals And Locations

Standard Reverse Warning Decal - 6

Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal(s) above the instrument housing. The decals shown here are provided for identification and location purposes only. The text found on the decals is:

VEHICLE CAPABLE OF EXCESSIVE REVERSE SPEED!

Reverse operation may be dangerous even at low speeds. Steering control becomes difficult in reverse. Misuse of reverse may result in injury. Avoid turning at sharp angles in reverse.

Transmission may not always be in the gear indicated by the shift lever. Always apply throttle slowly.

On machines with reverse it is especially important to maintain track tension as specified in the Owner’s Manual. If specified track tension is not maintained severe damage to the machine may occur, which may result in loss of vehicle control. Loss of vehicle control may result in severe personal injury or death.

For more information: See Operator’s Safety and Maintenance Manual supplied with reverse kit.

SHIFT PATTERN

Make sure lever is shifted completely to forward or reverse position. Do not force into reverse. If not able to shift to reverse, apply throttle gently to move vehicle. CAUTION: Do not attempt to shift until machine has come to a complete stop or chaincase damage may occur.

SAFETY

Safety Decals And Locations

Electronic Reverse Warning Decal - 7

Some Polaris snowmobiles are equipped with electronic reverse and will have this electronic reverse decal:

Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always:

S Look behind before

and while backing

S Avoid sharp turns. S Shift to or from reverse only when stopped. S Apply throttle slowly. S For more information, see your Owner’s Manual.

Operation Warning Decal - 8

The console of your machine has a WARNING decal. The location of this decal will depend on the model you own.

The decals shown here are offered for identification purposes only. The text of the decal is printed on the next page.

SAFETY

Safety Decals And Locations

Operation Warning Decal Text:

Read and understand warnings and the Owner’s Manual before

operation. Severe injury or death can result from not heeding the warnings.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Night riding, limited visibility, or excessive speeds may cause over-

driving of headlights resulting in insufficient time to react to terrain changes or avoid unexpected obstacles.

S This vehicle is capable of high speeds. Buried objects or uneven

terrain can cause loss of control. Exercise extreme caution when operating in unfamiliar terrain.

S This vehicle is designed for adult use only. The vehicle size, speed

capabilities and control requirement prohibit operation by children.

S Operating this vehicle with a passenger (On approved models only)

reduces your ability to control the vehicle due to the added weight and change in weight distribution. Reduce vehicle speeds and allow added space for maneuvering, since steering control may be reduced.

S Always wear an approved helmet, eye protection and adequate

clothing while operating this vehicle.

S The Auxiliary Shut Off Switch is the primary means of stopping this

vehicle in case of an emergency and is located on the top of the throttle control assembly. Depress the switch to stop the engine and vehicle. Routinely check this switch for proper function with the engine idling.

S The steering and braking ability are greatly reduced when operating

on hard-packed snow, ice or when crossing roads. Reduced speed and extra care are required to maintain vehicle control.

S Carbide skags and studs enhance vehicle control on ice or hard-

packed surfaces. Care must be taken to maintain a proper balance of ski carbides to track studs to maintain proper vehicle control. (See the Owner’s Manual for proper use of traction accessories.)

S Never permit a guest to operate this vehicle unless the guest has

read the Owner’s Manual and warnings.

SAFETY

Safety Decals And Locations

Caution Decal - 9

The hood of your snowmobile contains a CAUTION decal. The location of this decal will depend on which model you own:

BEFORE STARTING ENGINE:

Check throttle and brake for proper operation. Check to see that hood is securely latched. Check surroundings to verify clear operation area. Determine that steering is free and functional.

BRAKE LEVER LOCK: May relax when used for long periods. Do not leave brake engaged for more than five minutes.

ALWAYS: Be seated and in position to control vehicle. Stop engine before attempting adjustments. Know the limitations of the vehicle and your skills as a driver. Understand your Owner’s Manual. Wear clothing designed for snowmobiling.

Stops from high speed may cause fading or unexpected loss of braking ability.

Oil injection system: Unmixed fuel only. Check oil level when refueling.

If you do not have the Owner’s Manual for this vehicle, call 1-800-324-3764 to have one provided at no charge.

SECTION 3 - FEATURES AND CONTRO LS

Location of Controls 36 - 38...................

Features 39 - 41..............................

Section 3 illustrates the locations of your snowmobile’s controls and features.

FEATURES AND CONTROLS

Location of Controls

NOTE: Your machine may not look exactly like the illustration, but these controls are found in the same general area on all machines.

1. Fuel Filler Cap (some models have a fuel gauge in the cap)

2. Ignition Switch

3. Brake Lever

4. Speedometer (may include indicator/warning lights)

5. Tachometer (may include indicator/warning lights)

6. Engine Stop Switch (Push/Pull) Operation found on page 86.

7. Throttle Control

8. Hood Hold Down Straps

9. Recoil Starter Handle

10. Choke Control

FEATURES AND CONTROLS

Location of Controls

NOTE: 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 for a list of features on your machine. Accessories are available from your Polaris dealer.

1. Headlight Dimmer Switch (2 Position)

2. Park Brake

3. Handlebar Grip Warmer Switch

4. Thumbwarmer Switch

5. Electronic Reverse Button

6. Electronic Shock Control Button

7. Tether Switch

FEATURES AND CONTROLS

Location of Controls

NOTE: 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 for a list of features on your machine. Accessories are available from your Polaris dealer.

1. Reverse Indicator Light

2. Electronic Fuel Gauge

3. Temperature Light

4. Electric Shock Absorber Gauge

Features

FEATURES AND CONTROLS

1. Hood 12. Suspension

2. Headlight 13. Nosepan

3. Windshield 14. Trailing Arm

4. Handlebar 15. Skis

5. Seat 16. Front Bumper

6. Storage/Rear 17. Console

7. Taillights 18. Rear Bumper

8. Backrest 19. Passenger Hand Hold

9. Tunnel Extension 20. Lifting Hand Hold

10. Passenger Hand Hold Strap 21. Snow Flap

11. Track

FEATURES AND CONTROLS

Features

1. Hood 12. Suspension

2. Headlight 13. Nosepan

3. Windshield 14. Trailing Arm

4. Handlebar 15. Skis

5. Seat 16. Front Bumper

6. Storage/Rear 17. Console

7. Taillights 18. Rear Bumper

8. Backrest 19. Passenger Hand Hold

9. Tunnel Extension 20. Lifting Hand Hold

10. Passenger Hand Hold Strap 21. Snow Flap

11. Track 22. Hood Closures (Edge

Models Only)

Features

FEATURES AND CONTROLS

1. Hood 12. Suspension

2. Headlight 13. Nosepan

3. Windshield 14. Trailing Arm

4. Handlebar 15. Skis

5. Seat 16. Front Bumper

6. Storage/Rear 17. Console

7. Taillights 18. Rear Bumper

8. Backrest 19. Passenger Hand Hold

9. Tunnel Extension 20. Lifting Hand Hold

10. Passenger Hand Hold Strap 21. Snow Flap

-NOTES-

SECTION 4 - THE PERFECT FIT

Front Suspension Adjustments 44 - 48.........

Rear Suspension Adjustments 49 - 58.........

Handlebar Adjustment 59.....................

Backrest Adjustment 59......................

Accessories 60 - 63..........................

Polaris offers a wide range of adjustments so t hat every machine m ay be set up to suit individual needs. This section explains how to tailor the suspension and other features for an optimum riding experience.

THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before fine-tuning adjustments are made.

Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed, riding position, etc.) until the best ride is achieved. Adjustments should be made to one area at a time in order to properly evaluate the change.

All snowmobile suspensions have a front and a rear suspension, each of which has adjustment options.

Independent Front Suspension (IFS)

The IFS is made up of the skis (1), front shocks and springs (2), and the components that connect these parts to both the steering, such as the radius rods (3), and to the machine itself, such as the trailing arms (4). Front suspension adjustment options are limited to the front shocks and springs.

NOTE: Although the front suspension on your machine may not look exactly like the illustration, it will have the same parts and functions as those illustrated.

IFS Adjustment Options

DFront shock spring preload DOptional springs DOptional valving (if equipped with RYDE FX DIndy Select (if equipped)

t or Foxt Shocks)

THE PERFECT FIT

Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page145 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 spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. To determine if your machine is using full travel of the ski shock, push the jounce bumper down as far as it will go on the shock rod and test ride the machine. The bumper will move up on the rod in direct relation to the amount of travel. If the shock travel i s full, the bumper will be seated at the top of the shock.

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Preload Adjuster Nut

THE PERFECT FIT

Front Suspension Adjustments

Adjusting Front ShockSpring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the left and right sides of the machine are at the same adjustment.

To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload. In the illustrations at right, B indicates high preload and C indicates low preload.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension. Decreasing the spring preload too much may allow the upper spring retainer to fall off. Always leave at least one thread showing above the nut (A).

CAUTION

Always leave one thread showing above the adjuster nut. On models equipped with a plastic adjuster nut, if the nut is unscrewed from the threaded body, the nut will break.

THE PERFECT FIT

Front Suspension Adjustments

If the spring preload is at its maximum and you want more adjustment:

DRemove the existing spring and install the next highest rate spring, or DChange the shock valving on Fox DIncrease compression damping on Indy Select shocks (PE 52)

See your dealer for details. NOTE: Some models do not have shocks with thread adjustable

spring preload.

Changing Shock Valving

If you find that spring preload adjustment alone is not sufficient, changing the valving of your Foxt or RYDE FXt shocks may give you the ride adjustment you want. The purpose of shock valving is to control the stiffness of the shock’s compression.

t and RYDE FXt shocks, or

WARNING

Changing shock valving on Foxt and RYDE FXt shocks requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. This work should be performed by a Polaris dealer.

THE PERFECT FIT

Front Suspension Adjustments

Indy Select IFS Shock

Some snowmobiles are equipped with Indy Select IFS shocks, which allow you to make adjustments to the compression valving of the front shocks by turning adjustment screws (A) located near the base of the shocks.

By turning the screw clockwise, the compression of the shock increases, stiffening the ride. By turning counterclockwise, the compression decreases, softening the ride.

The factory setting is in the softest position (screw all the way out counterclockwise). If bottoming occurs, the Indy Select feature should be used to achieve the desired ride effect. One-half turn will affect the ride considerably. There are about three turns of adjustment available. If experimenting with this adjustment feature, turn the screw only 1/4 turn at a time. And always adjust both shocks equally.

THE PERFECT FIT

Rear Suspension Adjustments

Rear Suspensions

Polaris has six different rear suspension packages, each designed and set up t o deliver a soft ride under average riding conditions. Rider weight, riding style, t rail conditions, and vehicle speed all affect suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.

A decal outlining rear suspension set-up options is located either under the hood or on the clutch cover. It provides a guideline for initial suspension set-up. Additional adjustments can be made from this point. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see your dealer.

Suspension Performance Tips

DRider 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 set-up. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride.

DIn deep snow, a new Hi-fax will offer improved performance over

worn Hi-fax. It can also improve top speed.

DWhen riding on ice or hard-packed snow, adding a set of bogie

wheels to the rail may enhance the machine’s performance. Bogie wheel kits are available from your dealer.

DPolaris offers track kits for improved flotation in deep snow. See

your dealer for assistance.

IMPORTANT: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.. Grease rear suspension pivots before adjusting the rear suspension. Refer to Suspension Maintenance on pages 148-149.

THE PERFECT FIT

Rear Suspension Adjustments

Rear Suspension Initial Spring Preload Setting EDGE RMK (Sag Method)

T o set up the EDGE RMK rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.

Take this measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the suspension.

Next, have the rider drop down hard on the seat and bounce up and down several times, collapsing t he rear suspension. With the rider seated, measure the distance between the ground and the rear bumper at the exact location used for measurement X. This is measurement Y.

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration or the decal found under the hood for reference. The ideal amount of sag for the EDGE RMK rear suspension is four inches (X-Y=4).

If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment, optional torsion springs (softer or stiffer, respectively) may be required. This is only an initial setup, and final spring preload may vary based on rider preference and riding conditions.

THE PERFECT FIT

Rear Suspension Adjustments

Rear Spring Tension

To adjust rear torsion spring t ension, rotate the three-position cam using the engine spark plug tool.

Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information.

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.

1 - Turn screw clockwise to stiffen compression 2a - Limiter strap in high position increases ski pressure 2b - Limiter strap in low position decreases ski pressure 3a - Turn t he knob to the left for a softer ride 3b - Turn the knob to the right for a stiffer ride 4a - Soft Tension - long end of cam to front 4b - Medium tension - short end of cam up 4c - Firm tension - long end of cam up

THE PERFECT FIT

Rear Suspension Adjustments

Rear Suspension Initial Spring Preload Setting Xtra-10, EDGE and Xtra Lite (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 and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration or the decal found under the hood for reference. The ideal amount of Sag for the EDGE rear suspension is four inches (X-Y=4).

If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment, optional torsion springs (softer or stiffer, respectively) may be required. This is only an initial set-up, and final spring preload may vary based on rider preference and riding conditions.

THE PERFECT FIT

Rear Suspension Adjustments

Rear Torsion Spring Adjustment - Xtra-12

To adjust rear torsion spring tension, rotate the two-position cam using the engine spark plug tool.

1a - Soft Tension - long end of cam to front

1b - Medium Tension - short end of cam up

Different rate torsion springs are available if greater tension is desired. Contact your dealer for more information.

Rear Torque Arm Adjustment - SKS Models

On SKS models only, the rear torque arm may be lowered from the stock mounting position (A) to an optional position beneath t he tunnel bend line (B).

Install a replacement bolt into the stock mounting position t o secure the rear suspension mounting pad to the tunnel. See your dealer for more information.

Moving the rear torque arm below the tunnel will improve deep snow mobility.

THE PERFECT FIT

Rear Suspension Adjustments

Indy Select Front Track Shock

Some snowmobiles are equipped with the Indy Select front track shock, which allows the driver to make adjustments t o the compression valving by turning the screw located near the base of the shock.

Adjustment

Locate the adjustment screw (A) near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride. There are approximately three full turns of adjustment available.

THE PERFECT FIT

Rear Suspension Adjustments

Indy Select Rear Shock

Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock.

Adjustment

If bottoming continues after the screw has been turned fully clockwise, the torsion spring should be adjusted (see page 53). Return the screw to its original starting position after the torsion spring has been tightened.

THE PERFECT FIT

Rear Suspension Adjustments

Optional Coil Springs

Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information.

Position Sensitive Shock (PPS)

There are no external adjustments on the position sensitive shock. There is a performance PPS kit available for increasing damping. If you desire to have the internal valving changed, consult your dealer, or refer to the suspension troubleshooting decal located under your hood or on the clutch guard.

Suspension Coupling

On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other . There are two types of rear suspension coupling.

Front To Rear Coupling and the Front Rear Scissor Stop (FRSS)

The front rear scissor s top (FRSS) couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm.

When hitting a bump, the front torque arm starts to compress. The FRSS links that movement to the rear torque arm, causing it to compress and raise the rear suspension up as one, allowing the suspension to hit t he bump only once and eliminating kickback. Your FRSS is preset at the factory. Do not make any adjustments to the position of the FRSS or your ride will be compromised.

THE PERFECT FIT

Rear Suspension Adjustments

Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS)

The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.

Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS. This dot is on the longest end of the scissor stop.

Rear Rear Scissor Stop ( RRSS) - Attributes

Moving the R RSS to a higher position, or forward hole, will have the following effects on the suspension:

DReduced weight transfer. DImproved chatter bump ride. DImproved cornering performance.

THE PERFECT FIT

Rear Suspension Adjustments

Weight Transfer During Acceleration

Xtra-10 and EDGE Rear Rear Scissor Stop (RRSS)

The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the rear rear scissor stop (RRSS). The RRSS is located in the best overall trail riding position when delivered from the factory.

To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position with the scissor stop tool (1) located in your tool kit.

To increase weight transfer or ski lift during acceleration, move the RRSS to the rearward hole on high position. The RRSS may also be rotated to a lower position for even more weight transfer if desired.

A - Stock Position - This setting is most desirable for trail riding.

B - Medium or High Position (standard hole location) - This setting will decrease weight transfer.

C - Rearward Upper Position (optional hole location - This setting will increase weight transfer.

NOTE: Your dealer can help you with initial set-up and additional set-up instructions to help you achieve your optimum ride.

Xtra-12 Rear Rear Scissor Stop (RRSS)

The RRSS on Xtra-12 suspensions is not adjustable.

THE PERFECT FIT

Handlebar Adjustment

Follow these steps to adjust the handlebars for a personal fit. 1 Remove the handlebar cover to

expose the handlebar and the four adjuster block bolts (A).

2 Using a 7/16″ (11 mm) wrench,

loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).

NOTE: It may be necessary to pry the adjuster blocks apart with a screw driver.

3 Adjust the handlebar to the desired height. B e sure handlebars, brake

lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of t he machine when turned fully to the left or right.

4 Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (1.5-1.8

kg/m).

5 Replace handlebar cover.

Backrest Adjustment

The passenger backrest on some models is adjustable.

To move the backrest forward or backward, lift the adjustment lever on the left side (1).

When adjusting the backrest from a passenger position to a single rider position, rotate the backrest cushion adjustment knobs (2) until the proper angle is reached.

Thegrabbarshavefiveheight adjustments. To raise or lower the grab bar, remove the grab bar adjuster knob (3), position the grab bar at the desired height, and reinstall the knob.

Some models are also equipped with passenger handwarmers. The switch (4), located under the left--hand wind deflector, has three settings: High, Off, and Low.

To lengthen or shorten the backrest cable, lift the cable until spring tension is felt and lock the jam nut.

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.

NOTE: The accessory tether switch is available for all models. Order PN 2870668.

Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in:

DNon-compliance with government/industry requirements DVoiding of warranty DPersonal i njury to self or others

This applies to, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use ap- proved Polaris parts. Please see your Polaris dealer for service.

THE PERFECT FIT

Accessories

Traction Products

Another way to tailor your machine is to install traction products. See your dealer if you about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.

NOTE: Polaris does not recommend the use of traction products on WideTrak snowmobiles.

CAUTION

If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear.

Never add shims to the wear strip. Track damage will result because of lack of clearance between upper carrier wheels and track.

Use of studs longer than 1″ (2.5 cm) on machines equipped with center coolers will result in center cooler damage or damage to the tunnel.

Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

WARNING

Loss of control can result in serious personal injury or death. Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard-packed snow or ice. See your dealer for assistance.

THE PERFECT FIT

Accessories

Traction Products

IMPORTANT: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.

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. The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control. Similarly, if your machine is equipped with carbide skags or you’re adding them, it may be necessary to add track studs to maintain proper vehicle control. Proper balance must be maintained between the number of studs and the length of carbide on skags. The more studs used, the longer the carbide on the skags should be. See your dealer’s track studding chart for recommended studding and skags.

Inspect skags and studs frequently. Worn studs or skags m ay reduce steering and braking control on hard-packed snow and ice. Replace worn studs and skags to maintain proper balance and vehicle control.

When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. See your dealer for more information.

CAUTION

Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8″ (2.86 cm) from the edge of the outer belt.

THE PERFECT FIT

Accessories

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information.

Some models are manufactured with tunnel wear strips or wear strip coolers installed. Refer to your Owner’s Manual Supplement to determine if your model has wear strips.

Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

Components as viewed from the rear of the track: 1 Top of tunnel 2 Wear strip 3 Track 4 Wearstrip mounting holes

CAUTION

Studs longer than 1″ (2.5 cm) on machines equipped with center coolers will cause center cooler damage.

Whenever wear strips are relocated, be sure there’s adequate stud clearance to the heat exchangers. Lack of clearance may result in damage to heat exchangers.

-NOTES-

SECTION 5 - GETTING READY TO RIDE

Check Before Starting Engine 66 - 70..........

DThrottle Freeplay DBrake DFluid Levels DSteering DMirrors DGear

Start the Engine and Check 71................

DLights DStop Switch DSkis and Track (cold/warm) DPre-ride warm-up

Certain items must be checked before each ride. This section explains procedures that must be performed before riding.

GETTING READY TO RIDE

Check Before Starting Engine

WARNING

Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation.

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.

Check Throttle and Brake for Proper Operation

The throttle and brake are the primary controls of your snowmobile. If either should malfunction, loss of control could result.

Make sure the throttle lever compresses evenly and smoothly. The lever should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, DO NOT start the engine. Have the throttle serviced immediately.

The need for a properly functioning brake is critical. Your snowmobile is equipped with the highest quality brake system available. Check the brakes for correct operation before starting the engine.

Throttle Safety Switch

Test the throttle safety switch system daily, before the machine i s operated.

GETTING READY TO RIDE

Check Before Starting Engine

Hydraulic Brakes

Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine.

Brake Lever Travel

When the brake lever is squeezed, it should move no closer to the handgrip than 1/2″ (1.3 cm) (A). A distance less than this indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 127.

Lever Feel

A hydraulic system multiplies the force of your hand squeezing the brake lever. Proper operation depends on an adequate supply of air and moisture-free hydraulic brake fluid in the system. If the brake lever feels “spongy” when squeezed, check the level and condition of the fluid. Also check for the presence of air in the fluid system. Refer to page 127 for more information, or see your dealer for service.

Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris brake fluid (PN 2870990).

WARNING

Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death.

GETTING READY TO RIDE

Check Before Starting Engine

Mechanical Brakes

Brake Lever Travel

Firmly depress the brake lever. Measure the distance (A) between the lever and brake block. The distance should be no more than 3/4″ (1.9 cm).

If the distance is greater than this recommendation, the brake cable must be adjusted. Refer to mechanical brake adjustment information on page 128.

GETTING READY TO RIDE

Check Before Starting Engine

Park Brake Lever Lock

Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the m achine to remain stationary; for example, when parked on an incline for a period of five minutes or less. To apply the lock, squeeze the brake handle and push forward on the brake lever lock. Hold the lock forward and release the brake handle.

If the brake handle is squeezed tightly enough, the lock will move freely into place. Do not force the lock or it may break. To release the lock, squeeze the brake handle until the lever returns to the unlock position. The park brake light on the console will light up when the park brake lever lock is set and the engine is running. It will also be lit when the service brake is in use. If the park brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer.

1. Brake Handle

2. Park Brake Lever Lock (not all models have a park brake)

3. Master Cylinder Reservoir / Cover

4. Fluid Level Indicator

WARNING

If the park brake lever lock is partially or entirely engaged while riding, overheating of the brakes could occur, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death.

GETTING READY TO RIDE

Check Before Starting Engine

Check for Proper Operation of Steering System

Manually turn the skis completely to the right and t o the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

Track Inspection

WARNING

Always inspect the track for damage before using the vehicle. 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.

Use of traction products such as studs increases the possibility of track damage and/or failure. Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods, break track edges, and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions.

NOTE: Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

Check for Securely Latched Hood

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.

GETTING READY TO RIDE

Start The Engine And Check

n Transmission: Make sure the reverse is not engaged before

starting your machine.

n Engine Stop Switch: Check the auxiliary shut-off switch for

proper operation. Push down t o stop the engine. Pull up to release and start the engine.

n Tether Switch: If equipped, check the tether switch for proper

operation.

n Lighting Check: Check the headlight (high and low beam),

taillight, and brake light for normal operation.

n Mirror Adjustment: Adjust your mirrors so they can be used to

their full advantage.

n Check Surroundings to Verify Clear Operating Area

Make sure you have a clear area all around your snowmobile, including an area clear of bystanders. There’s always the possibility of some sideways vehicle movement, of applying a little more throttle than intended, or of debris being thrown by the track. If the surrounding area is clear you before you start, you can devote your full attention to operating the snowmobile.

-NOTES-

SECTION 6 - OPERATION

Starting Y our Engine 74 - 75..................

Engine Break-In 76 - 77.......................

Track Warm-Up 78 - 79.......................

Fuel 80 - 82..................................

Oil 83 - 84...................................

Carburetion 85...............................

Engine Stop Switch 86.......................

Throttle Safety Switch 86.....................

Throttle Lever 87.............................

Emergency Stopping and Starting 88 - 89......

Reverse Operation 90 - 92....................

Daily Storage 92.............................

Towing 93...................................

Section 6 explains proper engine break-in, operation of features, and operating procedures.

OPERATION

Starting Y our Engine

WARNING

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 66.

Starting a Cold Engine (Manual Start)

Do not depress the throttle until the engine starts. 1 Turn key to “ON.” 2 Pull kill switch (shut-off switch) up to “RUN.” 3 Flip choke toggle to “FULL ON.” 4 Grasp starter handle and pull slowly until recoil engages; then pull to

start.

CAUTION

Don’t pull the starter rope to full extended position or allow it to snap back into the housing. Damage may result.

5 After the enginestarts, flip the choke toggle to the “OFF” position. If

the engine slows or wants to stop, use intermittent choking to the “HALF ON” position.

CAUTION

To avoid personal injury and/or engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

Starting Y our Engine

Starting a Cold Engine (Electric Start)

OPERATION

Do not depress the throttle until the engine starts.

CHOKE TOGGLE POSITIONS

1 Flip choke toggle to

“FULL ON.”

2 Pull kill switch (shut-off

Off

switch) up to “RUN.”

3 Turn key to “START”

and crank engine.

4 After the engine starts,

Half On

release the key to “ON” and flip the choke toggle to “OFF.” If the engine

slows or wants to stop, use intermittent choking to “HALF ON.”

5 WideTrak models can also be warmed up with the t ransmission in

neutral and the brake engaged. This will allow the engine to warm without engaging the drive system.

NOTE: Don’t leave the machine in this position for more than five minutes. Engine RPM should be at idle before shifting the transmission.

Starting a Warm Engine

1 Turn key to “ON.” 2 Pull kill switch (shut-off switch) up to “RUN.” 3 Grasp starter handle and pull slowly until recoil engages; then pull

to start.

If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4″ open), and pull the rope with your right hand. When the engine starts, immediately release the throttle.

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 gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

CAUTION

Never mix brands of two cycle oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage and the voiding of engine warranty. The only oil recommended for this system is Polaris injection oil. This oil has been specially formulated for all temperatures and has extreme cold flow characteristics.

Do not operate at prolonged full throttle for the first three hours of operation. Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts and allow them to break in slowly without damage.

Adequate snow coverage is necessary to properly break in your machine. Avoid operating on ice, hard-packed surfaces, or roads. Snow will provide the lubrication and cooling your snowmobile needs for proper break-in. Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.

Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the machine.

OPERATION

Engine Break-In

Oil Injection System

CAUTION

Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately.

Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are controlled by the oil pump and correspond to the engine’s RPM and throttle valve opening.

Variable Exhaust System

All snowmobile engines equipped with variable exhaust valves should use VES 2 Cycle Oil (see chart on page 77).

Lubrication

The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems. Use only Polaris products. We are continuously testing lubricants and provide the highest performance products available for your engine. Please refer to the table below to determine the preferred and acceptable oils for use in your engine.

Never mix other brands of oil. They may be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other.

Premium

2Cycle

Fan Cooled Good Better N/A

Liquid Cooled Good Better N/A

Liquid VES Good Better Best

Premium

Gold

VES

2Cycle

OPERATION

Track Warm-Up

WARNING

A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while performing this procedure. Do not use too much throttle during warm up or when track is free-hanging. Be sure the rear support is stable.

NOTE: The outside temperature will determine the amount of track warm-up required.

With the snowmobile securely supported by the rear bumper, and the track approximately 4″ (10 cm) off the ground, follow these steps to ensure proper warm-up of the engine, drive train, and track.

1 Start the engine and allow it to warm up two to three minutes. 2 Depress the throttle abruptly and allow the track to rotate several

revolutions.

3 Release the throttle, apply the brakes, shut off the engine and lower

the machine to the ground.

4 Grasp the skis by their front loops and move them from side to side.

This will loosen frozen snow from the ski bottoms, allowing the machine to move forward more easily.

OPERATION

Track Warm-Up

5 The engine, drive system and track are now properly warmed up and

the machine may be driven following normal safety practices.

WARNING

Always inspect for track damage before operating the snowmobile. Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death.

OPERATION

Fuel

Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engineand refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

OPERATION

Fuel

The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used.

Most Polaris engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible. NOTE: Some Polaris snowmobiles require premium gasoline. Check your Owner’s Manual Supplement to determine what type of fuel your machine requires.

Premium Fuel Switch

Some Polaris snowmobiles are equipped with a key function to adjust the timing on the machine as you change fuels. It’s very important to the life of your engine that you use this feature.

When using fuels with a pump-posted octane rating of 91 or higher, turn the key switch to “ON/PREM.” When the engine is started, a yellow “Premium Fuel” light illuminates on the instrument panel. When the key is in this position, the fuel must be a minimum of 91 octane.

Most high performance machines require the use of premium fuels. Substituting other fuels may cause engine damage.

Premium Fuel Setting

Regular Fuel Setting

CAUTION

Using lower than the recommended octane fuels or operating with obstructed fuel systems will lead to costly engine damage.

OPERATION

Fuel

Premium Fuel Switch

If you’re uncertain about the quality or octane rating of the fuel you use, turn your key switch to “ON/REG.” The “Premium fuel” light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not recommend using fuel with lower than 87 octane. Running your machine on “ON/REG” will help protect your engine from damage caused by low octane fuels.

Fuel Reserve Capacity

On models equipped with fuel reserve, there are approximately two gallons of fuel left in the tank when the fuel gauge reads “RES.”

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer (Polaris PN 2870505). Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

Never use deicers or additives containing methanol.

If you use oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used.

CAUTION

Prolonged exposure to petroleum based products may damage paint. Always protect painted surfaces when handling fuel.

OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light (standard on most models) will indicate when to add oil. However, always check the oil level when refueling.

CAUTION

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 be operated as long as oil is visible in the oil tank. If oil is not visible, continued operation may cause serious engine damage.

Never mix brands of two cycle oil. Serious chemical reactions may occur, causing injection system blockage This may result in serious engine damage and the voiding of engine warranty.

Always maintain the oil level above the tank’s low level line. This is especially important when the machine is operated in mountainous terrain. Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage.

OPERATION

Oil

Low Oil Level

Always do a visual check of the oil level when refueling. In the illustration, * indicates a low oil level. When the oil reaches the low level mark, add one U.S. quart of oil to the tank.

Always use a Polaris oil cap, never substitute. Your Polaris oil cap may be vented to allow proper oil flow.

NOTE: Not all models have a coolant bottle attached to the oil tank.

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 lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor, or clogged fuel filters. A rich mixture may be caused by snow build-up on t he pre-filter i n t he air intake system. Either condition may be caused by improper carburetor adjustment.

All carburetors have been preset at the factory for adequate fuel supply. Higher altitude operation may require different adjustments and settings. NOTE: RMK models are preset to operate at altitudes of 6000-9000 feet above sea level. See page 118 for more information. Your dealer has the training and tools required to perform any adjustments for you.

WARNING

Carburetor adjustments must be performed by your dealer, since mistakes may result in possible operator safety hazards as well as serious engine damage.

OPERATION

Engine Stop Switch

Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to “ON.”

Throttle Safety Switch

Test the throttle safety switch system daily before operation.

While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration (B). Apply a slight amount of throttle. A properly functioning switch must shut down the engine.

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

WARNING

If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine until the malfunction has been corrected by your dealer.

OPERATION

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 stops abruptly when the throttle lever is released: 1 Turn the ignition switch to “OFF. ” 2 Visually inspect the throttle cable and carburetor(s)to determine what

caused the safety switch to activate.

3 Test the throttle lever by compressing and releasing it several times.

The lever and cable must return to the idle position quickly and completely.

4 If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5 If the engine doesn’t start, take the snowmobile to an authorized

Polaris dealer for service.

Excessive free play in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start t he engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness. When these switches are disconnected, the ignition key switch must be used to s hut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping And Starting

Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 86 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jack shaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

WARNING

Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system. This overheated condition could cause sudden loss of brakes and/or fire, resulting in serious injury or death.

When traveling on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, resulting in brake failure.

OPERATION

Emergency Stopping And Starting

Starting

WARNING

To prevent serious injury, DO NOT wind the start strap around your hand. Keep all bystanders away from the snowmobile when using the emergency starting procedure.

Your machine is equipped with a tool kit containing essential t ools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. To use the emergency start strap:

1 Open the clutch guard. 2 Push on the inner

sheave of the clutch and rotate clockwise slightly to relieve belt tension.

3 Starting at one of the

tower struts, wind the strap counterclockwise around the clutch as shown.

4 Pull the strap using a sharp, crisp pull so the strap comes free of

the clutch.

OPERATION

Reverse Operation (Mechanical)

WARNING

Misuse of reverse can result in serious injury or death. This snowmobile is capable of high speeds in reverse. Reverse operation may be dangerous even at moderate speeds. Steering control becomes difficult in 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 i f resistance is felt. The gears may not always be aligned for shifting into reverse, and forcing the lever may cause damage. If resistance is felt, gently apply the throttle to move the gears to a different position and try to shift again.

The transmission may not always be in the gear indicated by the shift lever. Apply the throttle slowly until you’re sure which gear is engaged.

Sometimes the drive belt will drag in the drive clutch, causing slight tension in the transmission and making it hard to shift. Shutting the engine off will remove this tension and ease shifting. This should only happen during the break-in of a new belt or when the drive/driven clutch center distance is too long. If this is the case, belt tension adjustments should be made by your dealer.

OPERATION

Reverse Operation (Electronic)

WARNING

Reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. To avoid loss of control, always:

S Look behind before and while backing. S Avoid sharp turns. S Shift to or from reverse only when stopped. S Apply throttle slowly.

This reverse will only activate if the engine is below 4000 RPM. Make sure the vehicle is stopped and the engine is running at idle.

1 Make sure the area behind you is clear. 2 Push the yellow reverse button on theleft hand controlfor one second

and release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on theinstrument panel will indicate the machine is in reverse.

3 Slowly apply the throttle until movement starts and until you are

certain you are in reverse.

NOTE: The maximum engine RPM will be 6000 when in reverse. NOTE: If the engine has stopped running, the snowmobile will run

forward the next time it’s started.

CAUTION

To avoid personal injury and/or engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

OPERATION

Reverse Operation (Electronic)

Forward

When running in reverse, again push the yellow reverse button on the left-hand control for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off. Make sure the area around you is clear and apply throttle slowly until you’re certain you’re going forward.

NOTE: If the engine has stopped running, the snowmobile will run forward the next time it’s started.

Altitude Setting

At higher altitudes (above 6000 feet), the engine will require a different ignition setting to improve the success of this reverse system.

To set for higher altitude: start the engine and hold the button down until the light on the instrument panel flashes rapidly, then release the button. This is the setting for higher elevations. To set the reverse for lower elevations, remain holding the button down until the reverse indicator light blinks slowly. Once set, it’s held in memory until changed, whether the machine is running or not.

Daily Storage

At the end of your ride, park the snowmobile on a level surface and support it at the rear with the appropriate track stand. The track should be suspended approximately 4″ (20 cm) off the ground.

Remove the key and cover the machine.

NOTE: Polaris has accessory covers and track stands available to fit all models. See your dealer for more information.

OPERATION

Towing

For your safety, the proper function of a tow hitch must be understood before attempting its use.

WARNING

DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. No braking power can be applied to an object being towed with a rope.

Only a stiff metal pole connecting the towed object and tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the vehicle track and a person riding in the towed object.

Braking distances increase when towing loads. Slow down to maintain control. Tip-over can result in serious injury or death.

If the snowmobile is inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the t ow rope to the ski spindles (not the ski loops) to prevent damage to the steering components. Have a rider on the snowmobile to operate the brake and steering when necessary.

CAUTION

To prevent serious damage to the engine and drive system, always remove the drive belt from a disabled snowmobile before towing.

-NOTES-

SECTION 7 - MAINTENANCE

Polaris Recommended

Maintenance Program 96.....................

Maintenance Charts 97 - 98...................

Maintenance Log 99 - 100.....................

Lubrication 101 - 1 10.........................

General Maintenance 111 - 139................

Track Maintenance 140 - 143..................

Steering System 144 - 147....................

Suspension Maintenance 148 - 149............

Extended Storage 150 - 152...................

Battery 153 - 155.............................

This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance.

If you’re interested in more information about servicing your own machine, contact your dealer for a Polaris Snowmobile Service Manual.

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part

failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.

MAINTENANCE

Maintenance Chart

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 dealer.

Item Weekly or

Check brake operation and adjustment

Test engine stop switch Daily 71, 86

Test tether strap Daily 71

Test throttle safety switch Daily 66, 86

Throttle lever operation Daily 66, 86

Check operation of headlights, taillight, brakelight

Check park brake function Daily 69

Secure hood Daily 70

Check track alignment X 142

Steering arm and tie rod ends X

Throttle cable condition X

Coolant level X

Battery fluid level X

Check track tension X 141

Check chaincase oil level X 109

Check gearcase o il level X 109

Check drive chain tension X 123

Check drive belt condition X 132

Check and tighten loose suspension mounting bolts

Tighten ski saddle and spindle bolts

Check front limiter strap condition, tighten bolts

Check ski skags - replace when worn to half original diameter

Check Hi-fax thickness, replace when worn (Dealer)

Tighten rear idler wheel bolts X 142

before

long trip

Daily 66,124

Daily 71,129

X 149

X 62

X 149

150 M.

(240 km)

1000 M.

(1600 km)

2000 M.

(3200 km)

See

Page

MAINTENANCE

Maintenance Chart

Item Weekly or

Tighten idler adjusting bolt jam nuts

Check spark plug condition X 113

Inspect coolant filter, replace if necessary

Grease ski pivots X X X 101

Grease ski spindles X X X 101

Grease center steering arm(s) X X X 101

Lubricate steering post support bracket and pivot (aerosol)

Check cylinder base stud torque on all Polaris engines. (Specification: 32 ft. lbs ± 2 ft. lbs.) (Dealer)

Grease lower steering post pivot X X X 101

Grease driveshaft bearing (always perform before storage)

Check and drain water trap X X 116

Grease rear suspension pivot shafts

Grease jackshaft bearing (always perform before storage)

Lubricate throttle cable X X 108

Lubricate choke slide and cable X X 108

Check clutch alignment and offset X X 134

Check cooling system level, specific gravity

Inspect oil filter and replace X X 117

Inspect oil line condition X 117

Inspect fuel filter and replace X X 117

Check brake fluid level X X 126

Inspect fuel lines and replace X 117

Inspect exhaust system for weak or missing retaining springs

Inspect exhaust pipe for cracks or damage

Inspect clutch sheaves for damage, wear, belt residue

before

long trip

X 142

150 M.

(240 km)

X X X 108

X X X 101

X X X -

1000 M.

(1600 km)

X X 107

X X 119

2000 M.

(3200 km)

X 119

X 134

See

Page

Polaris 2002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual