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!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner
1
-NOTES-
2
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.
Copyright 2003
Polaris Industries Inc.
All Rights Reserved
Printed in the U.S.A.
3
TABLE OF CONTENTS
Section 1 - How to Use This Manual5 - 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 - Safety1 1 - 34.....................
This section describes safe vehicle operation and identifies warning
decals and their locations.
Section 3 - Features and Controls36 - 41......
This section illustrates the locations of your snowmobile’s controls and
features.
Section 4 - The Perfect Fit43 - 63..............
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Section 5 - Getting Ready to Ride65 - 71.......
This section explains procedures that must be performed before riding.
Section 6 - Operation73 - 93..................
This section explains proper engine break-in, operation of features, and
operating procedures.
Section 7 - Maintenance95 - 155..............
This section defines your role, and your dealer ’s role, in your
snowmobile’s regular maintenance.
Section 8 - Troubleshooting157 - 166..........
This section is a quick reference guide to solving problems.
Section 9 - Warranty170 - 175.................
This section contains specific warranty information.
4
SECTION 1 - HOW TO USE THIS MANUAL
Important Notes for Drivers6.................
Preservation Of The Environment7 - 8........
Vehicle Identification Numbers9..............
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.
5
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.
6
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.
7
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.
8
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
9
-NOTES-
10
SECTION 2 - SAFETY
Operator Safety12 - 27.......................
Safety Decals and Locations28 - 34...........
Section 2 describes safe vehicle operation and identifies warning decals
and their locations.
11
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.
12
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.
13
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.
14
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.
15
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.
16
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.
17
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.
18
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.
19
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.
20
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.
21
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.
22
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.
23
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.
24
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.
25
SAFETY
inMPH
t
tleAdde
d
ect
Clo
the
dPers
on)
LittleAddedEffectClothedPerson)
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
50403020100-10 -20 -30 -40 -50 -60
Calm50403020100-10 -20 -30 -40 -50 -60
5483727166-5-15 -26 -36 -47 -57 -68
104028164-9-21 -33 -46 -58 -70 -83 -95
1536229-5-18 -36 -45 -58 -72 -85 -99 -11
2032184-10 -25 -39 -53 -67 -82 -96 -110-12
2530160-15 -29 -44 -59 -74 -88 -104-118-13
302813-2-18 -33 -48 -63 -79 -94 -109-125-14
352711-4-20 -35 -49 -67 -82 -98 -113-129-14
402610-6-21 -37 -53 -69 -85 -100-116-132-14
Wind Speeds Greater
Than 40 MPH Have
Li
Eff
Little Danger
(For Properly
Actual Thermometer Reading (°F)
Equivalent Temperature (°F)
Increasing
Danger
Danger From Freezing of Exposed Flesh
Great
Danger
2
4
3
0
5
8
26
Operator Safety
inKPH
A
f
f
C
)
WIND CHILL CHART (°C)
SAFETY
Estimated Wind S peed
050-5-10-15-20-25-30-35-40
101-4-11-16-22-27-33-38-45-50
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)
50-5-10-15-20-25-30-35-40
Equivalent Temperature (°C)
Little Danger
(For Properly
lothed Person
Increasing
Danger
Danger From Freezing of Exposed Flesh
Great
Danger
27
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.
28
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