Polaris 2008 Widetrak LX, 2009 Widetrak LX Owner's Manual

WARNING

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.

WARNING

The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.

1

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world­wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a Factory Certified Master Service Dealer (MSD)
Technician.

Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces­sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus­tries Inc.

Copyright 2008 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2009 Widetrak LX Owner’s Manual
P/N 9921649

3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Features and Controls . . . . . . . . . . . . . . . . . . . 26

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 38

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 105

Suspension Troubleshooting . . . . . . . . . . . . 106

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 107

This section is a quick reference guide to solving general problems.

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 120

Record maintenance and service in the log for your reference and for
future owners of the vehicle.

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient ref­erence. It should remain with the snowmobile when the snowmobile is
sold.

When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make 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.

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.

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.

Protect and preserve your right to ride by joining your local trail riding
clubs.

Some of the illustrations and photos used in this manual are general rep­resentations. Your model may differ.

5

INTRODUCTION

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 that 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 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.

6

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in
the spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with one
of your existing keys, so if both keys are lost, the ignition switch must
be replaced.

Vehicle Model Number: ___________________________________________________

Tunnel VIN: ____________________________________________________________
(lower right side of the tunnel)

Engine Serial Number: ___________________________________________________
(right front side of engine crankcase)

Key Number: ___________________________________________________________

7

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym­bols are used. Become familiar with their meanings before reading the
manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

8

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed rec­reational vehicle. Follow the recommended maintenance program out­lined beginning on page 61 of this manual to ensure that all critical
components on the snowmobile are thoroughly inspected by your dealer
at specific mileage intervals.

WARNING

Driving a snowmobile requires your full attention. DO NOT 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.

9

SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially
exposed for proper operation.

Stay Clear of Engine

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.

WARNING

Serious injuries may result if hands, feet, or
clothing become entangled in the track. Be
alert when riding, and remain properly
seated to stay clear of the track.

Never hold the snowmobile up or stand
behind it while warming up the track. A loose
track or flying debris could cause serious
injury or death. We recommend having your
dealer perform all track service and align­ment procedures.

WARNING

Serious injury can occur if fingers or clothing contact the moving parts of an
engine. Always stop the engine before attempting adjustments.

10

SAFETY

Operator Safety

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone. If
it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment 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 telephone.

For added protection, carry the following items on your snowmobile at
all times:

Riding Position

Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under many conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

• Tow Rope • Owner's Manual

• Extra Oil • First Aid Kit

• Fuel Deicer • Tool Kit

WARNING

Improper riding position may reduce control and could result in serious injury
or death. Always ride in a position that allows for control of your vehicle.

11

SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be com­fortable when riding. Be aware of the
weather forecast, especially the
windchill, and dress accordingly. See
the chart on page 22.

Helmet

Wearing a helmet can prevent a
severe head injury. Whenever riding a Polaris vehicle, always wear a
helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.

Approved helmets in Europe, Asia and
Oceania bear the ECE 22.05 label. The
ECE mark consists of a circle surrounding
the letter E, followed by the distinguishing
number of the country which has granted
approval. The approval number and serial
number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When­ever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

WARNING

Avoid wearing loose clothing or
long scarves, which can become
entangled in moving parts and
cause serious injury.

E

4

051039

0006.31

12

SAFETY

Operator Safety

Cargo Overload

Too much 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.

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.

Rider Capacity

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.

Driving 2-Up - Some Polaris snowmobiles are designed for up to 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 23 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.

13

SAFETY

Excessive Speed

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. 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.

WARNING

High speed driving, especially at night, could result in serious personal injury
or death. Always reduce speed when driving at night or in inclement weather.

14

SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you’re snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy 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.

RR

15

SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped
with a shovel, probe and avalanche
beacon.

You don’t have to be snowmobiling on a slope for an avalanche to occur.
Be aware that all of the snow is connected. You may be riding on a flat
slope or snow covered road, but if the snowpack above is unstable
enough you can trigger an avalanche on a steeper slope above you.
Always be aware of snow conditions above you as you travel in moun­tainous terrain.

Before riding in mountainous terrain, call or log on to your local ava­lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi­tions, contact local law enforcement in your area, or visit the American
and Canadian online avalanche centers at www.avalanche.org.

16

SAFETY

Operator Safety

Ice and Snow Build-up

Before driving, manually turn the skis to the left and right to be sure ice
and snow are not interfering with full left and right steering. If 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.

Driving on Slippery Surfaces

Excessive shifting of operator body weight when turning on hard­packed 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.

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.

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.

17

SAFETY

Operator Safety

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 momentum. 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.

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.

18

SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep the
clutch engaged, allowing the engine’s compression to help slow the
machine and keep it from rolling freely downhill.

Clutch Guard

Do not operate the engine with the clutch guard removed.

The clutch guard is designed to protect the operator from metal parts if
the clutch should fail. Although the chance of failure is extremely
remote, don’t defeat the purpose of the guard by removing it. It’s pro­vided for your safety.

Drive Belt

Do not operate the engine with the drive belt removed.

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

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.

19

SAFETY

Operator Safety

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

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

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. 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. See Starting the Engine on page 45.

Maneuverability

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

20

SAFETY

Operator Safety

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension
and, on liquid cooled models, cooling for the engine, adequate snow
cover is a requirement for operation of your 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 the
snow.

NOTICE: 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.

WARNING

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

21

SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most 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.

• 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.

• Before allowing someone else to use your snowmobile, know the
extent of their operating skills. Check to see if 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.

• Don't "jump" your snowmobile over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. 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.

• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.

• When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive defen­sively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile
unattended.

22

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

WIND CHILL CHART (°C)

Wind

Speed

in

MPH

Actual Thermometer Reading (_F)

40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

Equivalent Temperature (_F)

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

-20 -25 -30 -35 -40 -45

5 3631251913 7 1 -5-11-16

-22 -28 -34 -40 -46 -52 -57 -63

10 34 27 21 15 9 3 -4 -10 -16

-22 -28 -35 -41 -47 -53 -59 -66 -72

15 32 25 19 13 6 0 -7 -13

-19 -26 -32 -39 -45 -51 -58 -64 -71 -77

20 30 24 17 11 4 -2 -9 -15

-22 -29 -35 -42 -48 -55 -61 -68 -74 -81

25 29 23 16 9 3 -4 -11 -17

-24 -31 -37 -44 -51 -58 -64 -71 -78 -84

30 28 22 15 8 1 -5 -12

-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

35 28 21 14 7 0 -7 -14

-21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

40 27 20 13 6 -1 -8 -15

-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

45 26 19 12 5 -2 -9 -16

-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

50 26 19 12 4 -3 -10 -17

-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

55 25 18 11 4 -3 -11

-18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

60 25 17 10 3 -4 -11

-19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

Frostbite in >>

30 min. 10 min. 5 min.

Wind

Speed

in

KPH

Actual Thermometer Reading (_C)

5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

Equivalent Temperature (_C)

Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28

-31 -34 -37 -40 -43 -46

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29

-32 -36 -39 -43 -46 -50 -53 -57

16 2 -2 -6 -10 -13 -17 -21 -24 -28

-32 -36 -39 -43 -47 -50 -54 -58 -62

24 1 -3 -7 -11 -15 -19 -22 -26

-30 -34 -38 -42 -45 -49 -53 -57 -61 -65

32 0 -4 -8 -12 -16 -20 -24 -28

-32 -36 -39 -43 -47 -51 -55 -59 -63 -67

40 -1 -5 -9 -13 -17 -21 -25 -29

-33 -37 -41 -45 -49 -53 -57 -61 -65 -69

48 -1 -5 -9 -13 -18 -22 -26

-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

56 -2 -6 -10 -14 -18 -22 -26

-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

64 -2 -6 -10 -15 -19 -23 -27

-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

72 -2 -7 -11 -15 -19 -23 -28

-32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

80 -3 -7 -11 -15 -20 -24 -28

-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

88 -3 -7 -12 -16 -20 -24

-29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

96 -3 -8 -12 -16 -21 -25

-29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

Frostbite in >>

30 min. 10 min. 5 min.

23

SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protec­tion. Read and follow the instructions of the decals and other warnings
on the snowmobile carefully. If any of the decals depicted in this manual
differ from the decals on your snowmobile, always read and follow the
instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.

Clutch Cover Warning

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

WARNING
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.

Air Box Warning

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

CAUTION
Do not operate above 40 mph with hood-to-air box foam removed

or engine failure will result.

Passenger Warning

Your Polaris Widetrak snowmobile is
designed for the operator and one pas­senger. For more information on oper­ating with a passenger, see Page 12.

WARNING
This vehicle is designed for opera-

tor and ONE passenger

+

24

SAFETY

Safety Decals and Locations

Track/Seat Warning

The track/seat warning decal is on the
rear of the tunnel:

WARNING
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.

Reverse Warning

Polaris Widetrak snowmobile is
equipped with standard reverse.
The reverse warning decal is
located above the instrument hous­ing.

WARNING
Reverse operation, even at low

speeds, can cause loss of con­trol resulting in serious injury
or death. To avoid loss of con­trol, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.
NOTE: For more information, see Owner's Manual.

+

+

25

SAFETY

Safety Decals and Locations

Operation Warning

An operation warning decal is present on the console of all Polaris
snowmobiles:

WARNING

• To avoid serious injury or death, read and understand all warnings
and the Owner’s Manual before operation. If manual is missing, con­tact a Polaris dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehi­cle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age
requirements.

• When operating with a passenger (on approved models only),
reduce speed and allow extra space for steering and stopping. A
passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you
should have a proper balance of ski carbides to track studs. See
Owner’s Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss
of braking ability.

• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.

• Before starting the engine, check throttle, brake, and steering for
proper operation. Make sure hood is latched. Be seated and in posi­tion to control the vehicle.

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

26

FEATURES AND CONTROLS

1. Fuel Filler Cap (may include a fuel gauge)

2. Ignition Switch

3. Brake Lever

4. Speedometer (may include indicator/warning lights)

5. Reverse Indicator

6. Mountain Bar

7. Engine Stop Switch (see page 54)

8. Throttle Control

9. Choke

10. Recoil Starter Handle

5

4

3

2

1

10

9

7

8

6

General

Representation

27

FEATURES AND CONTROLS

Some Polaris snowmobiles are equipped with special features. Controls
for these features are illustrated on this page. Not all models come with
these features. Refer to your Owner’s Manual Supplement.

NOTE: Accessories are available from your Polaris dealer.

1. Headlight Dimmer
Switch

2. Parking Brake
Lock

3. Handlebar Grip
Warmer Switch

4. Thumbwarmer
Switch

5. Electronic Reverse
Button

Fuel Valve

The fuel valve is located under the
hood. Turn the fuel valve off when­ever the snowmobile is stored or
parked.

1. Turn the valve clockwise to
turn off the fuel supply.

2. Turn the valve counter-clock-

wise to turn on the fuel supply.

2

5

4

3

1

ONOFF

28

FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Operator Seat

6. Passenger Hand Hold Strap

7. Cargo Rack

8. Taillights

9. Snow Flap

10. Track

11. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper (do not use for pulling or dragging the snowmobile)

15. Skis

Cargo Rack

Always secure cargo before operating. Do not exceed the rack weight
limit specified on the cargo rack decal. Do not allow a passenger to sit
on the seat back or the cargo rack.

14

1

2

3

4

5

6

8

9

11

10

12

15

13

7

29

FEATURES AND CONTROLS

Backrest

The backrest is adjust­able for either operator
or passenger use.

1. Loosen the upper
adjustment knobs to
raise or lower the
backrest.

2. Loosen the lower

adjustment knobs
to move the back­rest forward for
operator use or
rearward for pas­senger use.

3. Always tighten the

knobs

Operator/Passenger

Raise/Lower

30

THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and re­grease all suspension parts before making any fine-tuning adjustments.

Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail 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.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Front shock spring preload

NOTE: Optional springs

1

2

3

4

31

THE PERFECT FIT

Front Suspension Adjustments

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 is full, the bumper will be seated
at the top of the shock.

Shock Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Preload

Adjuster Nut

WARNING

Always verify ski alignment before making adjustments to the IFS. See page
94 to check alignment. If the skis are misaligned, see your dealer, as the
camber adjustment may also be affected.

1

3

4

5

2

32

THE PERFECT FIT

Front Suspension Adjustments

Shock Spring Preload

Increasing spring preload
will increase ski-to-ground
pressure. Decreasing spring
preload will decrease ski-to­ground pressure.

Front Springs

For models without exter­nally adjustable or revalv­able shocks, the front springs
can be changed if spring pre­load alone isn’t sufficient
and further adjustment is
desired to control suspen­sion stiffness. Special tools
are required to adjust front
springs. If you feel that your
front suspension needs
adjustment see your Polaris
dealer for more information.

Front
Shock
Washers

33

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action. Each rear suspension can be adjusted to suit rider
preference and deliver excellent performance for a given set of 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.

See your Polaris dealer for initial suspension setup information. Addi­tional adjustments can be made after initial setup. Make adjustments to
one area at a time so you can evaluate the change. For further assistance,
see your dealer.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a

worn rail slide. It can also improve top speed.

• When 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.

• Polaris offers track kits for improved flotation in deep snow. See your

dealer for assistance.

NOTE: 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. See page 67.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor­rect tension and alignment. Refer to the track tension maintenance sec­tion beginning on page 90.

34

THE PERFECT FIT

WideTrak Rear Suspension Adjustments

Rear Spring Settings

Rear spring adjustment is primarily a control for riding comfort. To
check for the recommended settings:

1. Lift the rear of the machine to relieve the rear springs.

2. Slowly lower the machine and measure the distance between the
ground and the running board.

3. Without letting the suspension settle, the rider should carefully
mount the snowmobile.

4. Measure the distance between the ground and the same spot on the
running board.

The difference between the two measurements should be approximately
1 1/2" (3.8 cm). If the difference is greater than 1 1/2", the rear spring
should be adjusted equally on both sides until the desired 1 1/2" drop is
obtained.

Compensating adjustments for heavy or light drivers or cargo loads can
be made by adjusting the rear spring eye bolt length. Adjust spring ten­sion so there is equal tension on the long leg of each spring.

NOTE: Rear spring settings will affect ski-to-ground pressure. If ski

pressure is too light it may be desirable to tighten the rear
springs for an increase in ski-to-ground pressure.

Eye Bolt

35

THE PERFECT FIT

Handlebar Adjustments

Standard Handlebar

Follow these steps to adjust handlebar angle at the handlebar block.

1. Remove the mountain bar by
removing nuts.

2. Using a 7/16-inch wrench,

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

NOTE: If necessary, pry the

blocks apart with a
screwdriver.

3. Adjust the handlebar to the

desired angle. Be sure the
handlebar, brake lever and
throttle lever operate
smoothly and do not hit the
gas tank, windshield or any
other part of the machine
when the handlebar is turned fully to the left or right.

4. Torque the front bolts first, then torque the rear bolts. Torque the

bolts to 11-13 ft. lbs. (15-18 Nm).

5. Reinstall the mountain bar.

Bar

Nuts

Bolts

Nuts

36

THE PERFECT FIT

Traction Products

nCarbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain.

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

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.

37

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile. From
map light to electric start, Polaris has the accessories that will help make
each ride more enjoyable. See your dealer for a list of accessories.

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Personal injury 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

approved Polaris parts. Please see your Polaris dealer for ser­vice.

38

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the refer­enced pages. Look for a checkmark (

n) on the referenced pages to

locate the pre-ride inspection items

Item See Page

Drive Belt Condition 83, 86

Steering System 42

Recoil Rope 43

Parking Brake Lock/Brake Lever/
Brake System

40, 41, 77

Auxiliary Shut-Off Switch (Engine Stop
Switch)

54

Ignition Switch 44

Taillight/Brakelight/Headlight 44

Suspension Mounting Bolts 96

Skags (Wear Bars) 95

Ski Saddle and Spindle Bolts 96

Hood Straps/Latches 43

Throttle Lever/Safety Switch 39, 54, 55

Rear Wheel Idler Bolts 91, 96

Track Alignment/Condition 42, 92

Rail Slide Condition 96

Chaincase Oil Level 69

Injection Oil Level 51

39

PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely and refer to it often. The manual
is your guide to safe and enjoyable snowmobiling experience.

n Throttle Lever

The throttle and brake are the primary controls of your snowmobile.
Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and
smoothly. When released, the lever should immediately return to the
idle position without binding or hesitation. If the throttle does not func­tion smoothly, or if you discover excessive lever freeplay, DO NOT start
the engine. Have the throttle serviced immediately. See page 55.

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated.
See page 54.

WARNING

Operating the vehicle with worn, damaged, or malfunctioning components
could result in serious injury or death. Never start the engine without check­ing all vehicle components to be sure of proper operation.

40

PRE-RIDE INSPECTIONS

Before Starting the Engine

n 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

Squeeze the brake lever. It should
move no closer to the handgrip
than 1/2 inch (1.3 cm). A smaller
distance indicates low brake fluid
level or air in the hydraulic sys­tem. See pages 78-79 or see your
dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Also check for the presence of air in the fluid sys­tem. See pages 78-79 or see your dealer for service.

Replace brake fluid at least every two years. We recommend the use of
Polaris DOT 4 high temperature brake fluid. See page 105 for the part
numbers of Polaris products.

WARNING

Continued use of “spongy” brakes may cause a complete loss of brakes,
which could result in serious injury or death. Always have the brakes serviced
at the first sign of sponginess.

1/2 inch (1.3 cm)

41

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Your snowmobile may have a
parking brake lever lock located
over the brake lever. Use the
brake lever lock only when you
want the machine to remain sta­tionary; for example, when
parked on an incline for a period
of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forward on
the lock. Hold the lock forward while releasing the brake lever.

NOTE: If the brake lever is squeezed tightly enough, the lock will move

freely into place. Do not force the lock or it may break.

The brake light will illuminate if the parking brake lever lock is set
while the engine is running. It will also illuminate when the service
brake is in use. If the parking brake light does not come on when the
parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return
to the unlocked position.

WARNING

If the parking brake lever lock is partially or entirely engaged while riding, the
brakes may overheat, resulting in brake damage. In extreme cases it could
cause a fire, which could result in serious injury or death. Always ensure that
the lever lock is completely disengaged before operating the snowmobile.

1

2

3

4

42

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

Manually turn the skis completely to the right and to the left. If any 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.

n Track

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 with inadequate lubrication could severely damage track rods,
break track edges, and cause other track damage. Examples of inade­quate 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 under

poor lubrication conditions voids the track warranty.

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.

43

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hood Latches

The hood of the snowmobile protects the operator from moving parts as
well as aiding in sound emission control and other functions. Under no
circumstances should your snowmobile be operated with the hood open
or removed. Always ensure that the hood straps are in good condition
and that the latches are securely in place before operating the snowmo­bile.

n Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the
seat latches are securely in place before every use of the snowmobile.

n Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the
knot securing the rope inside the handle is secure. If excessive wear is
found, see your Polaris dealer for replacement.

n Transmission

Make sure the transmission is not in reverse before starting the engine
(if equipped with reverse).

44

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the
switch down to stop the engine. Pull it up to allow restarting.

n Lighting

Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.

n Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

n Operating Area

Before driving, check your surroundings. Be aware of obstacles and
make sure bystanders are a safe distance from the machine.

n Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

45

OPERATION

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result

in serious engine damage, especially if the transmission is in
reverse. Never engage the starter when the engine is running.

1. Turn the fuel valve on. See
page 27.

2. Turn the key to the ON

position.

3. Pull the engine stop switch

up to the RUN position.

4. If starting a cold engine,

flip the choke toggle to
FULL CHOKE. Do not
use the choke if starting a
warm engine.

NOTE: Do not depress the throttle until the engine starts.

5. If equipped with electric start, turn the key to START to crank the

engine. Release the key to the ON position when the engine starts.

NOTICE: Don’t pull the starter rope to the fully extended position and

don’t allow it to snap back into the housing. Damage may
result. To avoid engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.

6. If not equipped with electric start, grasp starter handle and pull

slowly until the recoil engages; then pull abruptly to crank the
engine.

7. Repeat the cranking procedure as needed until the engine starts.

8. After the engine starts, flip the choke toggle to the OFF position. If

the engine slows or wants to stop, use intermittent choking to the
HALF CHOKE position.

CHOKE POSITIONS

OFF

HALF ON

FULL ON

46

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.

NOTICE: Excessive heat build-up during the first three hours of

operation will damage close-fitted engine parts. Do not
operate at full throttle or high speeds for extended periods
during the first three hours of use. Vary the throttle openings
and machine speeds to reduce friction on all close-fitting
machined parts, allowing them to break in slowly without
damage.

Use of any lubricants other than those recommended by
Polaris may cause serious engine damage. We recommend
the use of Polaris lubricants for your vehicle.

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

47

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 50.

NOTICE: Serious engine damage can occur without the proper

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

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES).
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of VES II 2 Cycle Oil for this
engine. See page 105 for the part numbers of Polaris products.

Never mix brands of oil. Serious chemical reactions can cause injection
system blockage, resulting in serious engine damage. Oils may also 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.

Slide Rail and Track Cooling

NOTICE: 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. Avoid operating on ice, hard-packed surfaces or
roads.

48

OPERATION

Track Warm-Up

Follow these steps to ensure proper warm-up of the engine, drive train
and track.

1. Use an appropriate stand to securely sup­port the rear of the snowmobile at the rear
bumper. The track should be approxi­mately 4 inches (10 cm) off the ground.

2. Start the engine and allow it to warm up

two to three minutes.

3. Depress the throttle abruptly and allow

the track to rotate several revolutions.

NOTE: It will take longer to warm up the

track sufficiently during colder out­door temperatures.

4. Release the throttle, apply the brakes,

shut off the engine and lower the machine
to the ground.

5. 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.

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

and the machine may be driven following normal safety practices.

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 warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Be sure
the rear support is stable.

WARNING

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. Always inspect for track damage before
operating the snowmobile.

49

OPERATION

Fuel

Your Polaris engine is designed to run on 87 octane non-oxygenated or
89 octane oxygenated pump gasoline. There’s a great deal of variability
in the quality of the 87 octane gasoline available, so we encourage the
use of premium fuel when possible. Do not use lower than 87 octane
fuel. Do not use fuel containing more than 10% ethanol (including E85).

NOTICE: Using fuels with a lower than recommended octane or

operating with obstructed fuel systems will result in serious
and costly engine damage. Always use the recommended
fuels for your machine.

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well
ventilated area.

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

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

• If gasoline spills 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. Engine exhaust
fumes are poisonous and can cause loss of consciousness or death in a
short time.

• Turn the fuel valve off whenever the snowmobile is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.

50

OPERATION

Fuel Reserve Capacity (Mechanical Gauge)

There are approximately two gallons of fuel left in the tank when the
mechanical fuel gauge reads RES.

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to 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. See page 105 for the part numbers of
Polaris products.

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

NOTICE: Prolonged exposure to petroleum based products may

damage paint. Always protect painted surfaces when
handling fuel.

51

OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 47 for
oil recommendations.

When the low oil indicator light is on, oil should be added before further
operation of the snowmobile. Visually check the oil level in the bottle.
The engine may 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 oil. Serious chemical reactions can cause injection
system blockage, resulting in serious engine damage. They may also 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.

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.

NOTICE: Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris 2­cycle oils for your snowmobile. Never mix brands.

Operating the snowmobile without proper engine lubrication
can result in serious engine damage. Always check the oil
level when refueling.

52

OPERATION

n Oil

Low Oil Level

Always do a visual check of the oil level when refueling. When the oil
reaches the low level mark, add one U.S. quart of recommended oil to
the tank. See page 47 for oil recommendations.

The Polaris oil cap on the oil tank may be vented to allow proper oil
flow. See your Polaris dealer for recommended replacement parts.

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 the pre-filter in the air intake system.
Either condition may be caused by improper carburetor adjustment.

WARNING

Improper carburetor adjustments may result in operator safety hazards as
well as serious engine damage. Always have your Polaris dealer perform any
carburetor adjustments.

53

OPERATION

Carburetion

Jetting Guidelines

Changes in altitude and temperature affect air density, which is the
amount of oxygen available for combustion. In low elevations and cold
temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.

RMK carburetors are preset to operate at altitudes of 6000-8000 feet
(1800-2400 m) above sea level (see page 74 for more information). Car­buretors must be re-calibrated if the snowmobile is operated outside this
production temperature and/or altitude range. The main jet installed in
production is not correct for all altitudes and/or temperatures.

NOTICE: A main jet that’s too small will cause a lean operating

condition and may cause serious engine damage. Jet the
carburetors carefully for elevation and temperature according
to the jetting charts. Refer to your Owner’s Manual
Supplement.

It’s the owner’s responsibility to ensure that the correct jets are installed
in the machine for a geographical area. Be very careful when jetting
down in warm weather. As the weather turns colder it will be necessary
to re-jet upward to prevent engine damage. When selecting the proper
main jet always use the lowest elevation and temperature that is likely to
be encountered.

54

OPERATION

n Engine Stop Switch

Push down on the engine
stop switch 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 the ON position.

n Throttle Safety Switch

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. Test the throttle
safety switch system daily before operation.

Test the throttle safety switch
system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it
to idle.

3. Hold the throttle lever pin
stationary by exerting pres­sure on the pivot pin in the direction shown in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in
serious injury or death in the event of an accident. 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 again
until the malfunction has been corrected by your dealer.

Stop Switch

55

OPERATION

n Throttle Lever

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor(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 the 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 shut 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.

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.

56

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. Refer to page 54 for more information about the
engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch 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 and result in brake failure.

57

OPERATION

Emergency Starting

Your machine is equipped with a tool kit containing essential tools for
emergency use. Snowmobiles equipped with electric start have a recoil
for emergency starting. If the recoil starter system fails, an emergency
start strap is provided in the kit.

Reverse Operation

Mechanical Reverse

Make sure the shift lever is shifted completely into forward or reverse
position. Some models are equipped with a reverse indicator light that
will help you make that determination.

Do not force the shift lever into reverse if resistance is felt. The 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.

WARNING

Improper reverse operation, even at low speeds, may cause loss of control,
resulting in serious injury or death. Damage will occur to the chaincase or
transmission if shifting is attempted when the engine is operating above idle
speed.

• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

58

OPERATION

To w i n g

Do not use the front bumper to pull or drag the snowmobile. The front
bumper is not designed for this type of use and may detach from the
vehicle if force is applied.

For your safety, do not attempt to using the tow hitch until you’ve read
the following warnings and understand the proper hitch functions.

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

NOTICE: Towing a disabled snowmobile with the drive belt in place can

result in serious damage to the engine and drive system.
Always remove the drive belt from a disabled snowmobile
before towing.

WARNING

Objects towed with a rope have no braking power and can easily collide with
the rear of the snowmobile or other objects, resulting in serious injury or
death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a
rope. Only a stiff metal pole connecting the towed object and the 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 snowmobile’s track and a person
riding in the towed object.

Braking distances increase when towing loads. Slow down to maintain con­trol of the snowmobile.

59

MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission con­trol information (ECI) label and a factory-installed emissions informa­tion hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. If your snowmobile is equipped with a
check engine light and it comes on, you must take your snowmobile to a
qualified dealer for diagnostic service. Specifications and adjustments
for engine tune-ups are located in the Service Manual, which is avail­able to your qualified service technician. Reverse (if equipped) must not
be engaged during engine tune-ups.

60

MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and
read the maintenance section of your owner's manual. You are responsi­ble for ensuring that the specified maintenance is performed. Polaris
recommends that you contact an authorized Polaris dealer to perform
any service that may be necessary.

61

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out­lined in this manual. Record maintenance and service in the Mainte­nance Log beginning on page 120.

The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1000 miles (1600 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 make adjust­ments to 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.

NOTICE: Hot components can cause damage to plastic. Always make

sure the exhaust system and engine have cooled before
tipping the snowmobile on its side for service or inspection.

62

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Offset Alignment
(without belt)

82 I I I

Drive Belt Condition 83 I I I I

Clutches (disassemble) 82 C C C

Belt Tension -- I I I I

Clutch Sheaves 86 I I I I

ENGINE

Engine Mounts -- I I I I

Recoil Rope 43 I I I I

Engine Mounting Plate -- I I I

Engine Torque Stop 87 I I I I

Cylinder Head Bolts -- I I I

Cylinder Base Nuts -- I I I I

Ignition Timing BTDC -- I I I

Spark Plug Condition 70 I I I I I

Exhaust Pipe 76 I I

Exhaust Retaining
Springs

76 I I I I

63

MAINTENANCE

Periodic Maintenance Interval Table

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing -- I I I I

Hose Condition -- I I I I

Fluid Leaks -- I I I I

Brake Pads 77 I I I I

Brake Disc -- I I I I

Parking Brakes 41 I I I I

Brake System 40,77 I

Brake fluid 78 R

FUEL MANAGEMENT

Pilot Air Screws -- I I I

Carburetor (synchronize) 52 I I I

Idle RPM -- I I I

Throttle Lever 39,55 I I I I I

Oil Pump Lever
(synchronize)

-- I I I

Throttle Cable 68 L L L

Choke Cable 68 I L L L

Vent Lines -- I I I I

Throttle Position Sensor -- I I I

Choke 68 I I I

Fuel Filter 75 R R

Fuel Lines 75 I I I I I

Oil Filter 75 R R

Oil Lines 75 I I I

Oil Change N/A R R I

Air Box -- I I I I I

Drain and Water Traps 73 I I I

64

MAINTENANCE

Periodic Maintenance Interval Table

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

ELECTRICAL

Auxiliary Shut-Off Switch 44 I I I I I

Throttle Safety Switch 39,54 I I I I I

Ignition Switch 44 I I I I I

Taillight 44 I I I I I

Brakelight 44 I I I I I

Headlight 44 I I I I I

CHASSIS

Ski Toe Alignment -- I I I

Suspension Mounting
Bolts

-- I I I I I

Steering Fasteners -- I I I I C

Rear Suspension
Fasteners

-- I I I I I

Suspension Shock Oil -- I I I I

Cooling Fins and Shroud -- I I I I

Drive Shaft Bearings 68 L L L I

Jackshaft Bearings 68 L L L I

Skags (Wear Bars) 95 I I I I I

Ski Saddle/Spindle Bolts -- I I I I I

Ski Pivots 66 L L L L I

Ski Spindle 66 L L L L I

Steering Arm(s) 66 L L L L I

Upper/ Lower Steering
Post Support Bracket

66 L L L L I

Hood Straps 43 I I I I I

Battery Fluid Level 97 I I I I I

Rear Wheel Idler Bolts
and Nuts

91 I I I I I

65

MAINTENANCE

Periodic Maintenance Interval Table

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Rear Suspension Pivot
Shafts

67 L L L

Camber Alignment -- I I I

Radius Rod Bushings -- I

Handlebar Centering -- I

Track Alignment 92 I I I I I

Track Tension 90 I I I I I

Front Limiter Strap -- I I I I I

Rail Slide Condition 96 I

Chaincase Oil N/A I I I R I

Gearcase Oil 69 I I I R I

66

MAINTENANCE

Lubrication

Suspension and Steering

Lubricate the suspension and steering components with Polaris Pre­mium All-Season Grease at 500 miles (800 km) and annually or every
1000 miles (1600 km) thereafter. A grease gun kit, complete with grease
and adaptors, is available to lubricate all fittings on Polaris snowmo­biles. See page 105 for the part numbers of Polaris products.

The illustration shows the lubrication points of suspension and steering
components. Grease the left and right spindles. Raise the front end of
the machine to permit better grease entry into the spindle area.

• Lubricate both of the front ski pivots at the fittings as shown.

• Grease the jackshaft and driveshaft clutch side bearings.

• Use an aerosol lubricant on the steering post support bracket.

• Grease the steering post lower pivot.

• Grease the rear suspension pivot shafts (raise the rear of unit).

+

+

+

+

+

+

67

MAINTENANCE

Lubrication

Rear Suspension
WideTrak Rear Suspension

+

+

+

+

+

68

MAINTENANCE

Lubrication

Jackshaft Bearing

The jackshaft bearing on your model may be equipped with a grease fit­ting, but this component is greased for life at the factory. Additional
lubrication is not required.

Driveshaft Bearing

Inject grease into the fitting on the
speedometer drive adaptor until
grease purges from inside or outside
the bearing seal (approximately two
pumps).

Throttle Cable

Lubricate the throttle cable lightly
with grease or oil. With the engine
off, turn the handlebars to the left
and lubricate liberally as shown.

Choke and Cable

Lubricate the choke slide and cables
lightly with oil or grease. Before
turning the engine off, operate the
choke intermittently to draw mois­ture out of the choke plunger area
and reduce the possibility of the
choke becoming frozen.

Coupler Greasing
(WideTrak)

Grease the couplers on the drive­shaft and jackshaft.

+

+

+

+

+

69

MAINTENANCE

Lubrication

n Gearcase Oil Level (WideTrak)

Check the gearcase oil level at
the intervals outlined in the
maintenance charts beginning
on page 65. Change the gear­case oil after the first 500 miles
(800 km), then every 1000 miles
(1600 km) or seasonally.

To check the oil level, place the
machine on a level surface. The
oil level should be between the
“safe” marks on the dipstick (1).
See your Polaris dealer for the
recommended oil for your
machine. Do not overfill.

Clean the magnetic plug (2)
every 500 miles (800 km) and
whenever checking or changing
lubricant.

NOTICE: Mixing brands or using non-recommended lubricants could

result in excessive wear to chain, sprockets and bearings.
Always use Polaris-recommended products for your vehicle.

1

2

70

MAINTENANCE

Spark Plugs

It’s very important to use the correct spark plug for your machine. A
spark plug with a heat range too high will cause engine damage. A spark
plug with a heat range too low will cause excessive fouling and engine
malfunctioning.

In selecting a spark plug heat range for production, a manufacturer
assumes that the engine will be operated under extreme heavy duty con­ditions and selects a spark plug that will protect the engine from internal
damage if the purchaser actually does operate the engine in this manner.
This selection could cause the customer who normally operates the
engine under medium or light duty to have spark plug failure.

NOTICE: A spark plug with a heat range too high will always cause

engine damage if the engine is operated in conditions more
severe than intended for that plug. Always use the spark
plugs recommended for your snowmobile. Refer to your
Owner’s Manual Supplement.

A new engine can cause temporary spark plug fouling due to the preser­vative added during the assembly process. Avoid prolonged idle speeds,
which cause plug fouling and carbonization.

• Use recommended spark plugs with the proper gap. Refer to your
Owner’s Manual Supplement.

• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).

• Always carry spare spark plugs in case of an emergency.

NOTICE: Using non-recommended spark plugs can result in serious

engine damage. Always use Polaris-recommended spark
plugs.

71

MAINTENANCE

Spark Plugs

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.

NOTE: Incorrect fuel mixture can often cause a spark plug to appear

too dark or too light in color. Before changing spark plug heat
ranges, be sure the correct main jet is installed in the carbure­tor(s). Refer to your Owner’s Manual Supplement.

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi­cates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates over-

heating, caused by use of an improper spark plug or incorrect
carburetion adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil, improper use of the choke, or incor­rect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to 18-22

ft. lbs. (24.4-29.8 Nm).

4. Reinstall the spark plug cap.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.

72

MAINTENANCE

Intake Filter

The intake foam filter and screen limits snow ingestion into the intake
system. When operating in loose powder snow, check the top of the
foam filter and screen periodically to remove any accumulation of snow.

NOTICE: Operating the snowmobile with the intake filters removed may

cause carburetor icing. The result will be poor fuel economy
or carburetor malfunction. Always reinstall the intake filters
before operating the snowmobile.

NOTE: These illustrations are general representations. Your model

may differ.

Intake

Foam Filter and Screen

Foam Filter

Air Intake Box

73

MAINTENANCE

Carburetor

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl water/sedi­ment traps located at the bottom of each carburetor. The trap, consisting
of a hose with a plug, should be drained about every 1000 miles (1600
km) and inspected for contamination.

Plug Cleaning Procedure

1. Turn the fuel valve off.

2. Position a container or shop towels to

catch the contaminated gasoline.

3. Slide the clamp away from the drain

plug and remove the drain plug from the
sediment tube.

4. Wipe residue from the plug and reinstall

it. Reposition and tighten the clamps.
Continue until all the traps have been
emptied.

WARNING

When draining the traps, fuel spillage will occur. Always work in a well venti­lated area away from anything that may cause the fuel to ignite, such as open
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline
warnings found on page 49.

Clamp

Drain
Plug

74

MAINTENANCE

Carburetor

The number stamped in the end of the main jet indicates the jet size. The
jet installed at the time of manufacture is not necessarily correct for your
elevation. It’s your dealer’s responsibility to make sure the correct main
jet is installed.

NOTICE: Operating the snowmobile with incorrect jetting can result in

serious engine damage. Have your Polaris dealer perform all
carburetor adjustments to ensure all adjustments are done
correctly.

Carburetor Adjustments

The frequency at which the carburetors are synchronized or balanced is
important. Properly adjusted carburetors can greatly improve engine
performance, fuel economy, engine life, and reliability.

If you notice any of the following conditions, the carburetor may need
adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

75

MAINTENANCE

Fuel Filter/Fuel Lines

The fuel filter is located inside the fuel tank. This component requires
no maintenance.

Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal dete­rioration from weather and fuel compounds may occur. Replace worn or
damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to

remove fuel lines may cause damage to the lines. If a fuel line
has been damaged or kinked, replace it promptly.

Oil Filter

The oil filter on your model is assembled into the oil sending unit
located in the bottom of the oil tank. This component requires no main­tenance.

If service is performed to the oil injection system, trapped air must be
bled from the system. See your dealer for instructions, or have your
dealer perform this service.

76

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 1000
miles (1600 km). To inspect, allow the engine and exhaust system to
cool completely. Open the hood and inspect the muffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.

Drive Chain Tension

Your WideTrak is equipped with an automatic chain tensioner. No main­tenance or inspection should be necessary.

WARNING

Hot exhaust system parts can cause serious burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.

77

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 40.

Brake pads must be replaced when the brake pad material becomes thin­ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is
available for replacing brake pads. See your dealer.

Brake Components

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material

(Replace when thick­ness is less than 1/16
inch/1.5 mm)

WARNING

Brake failure during operation can result in serious injury or death. Properly
functioning brakes are vital to your safety. Be sure the brake pads do not
drag on the disc and that brake lever travel is not excessive.

Always replace brake pads when the brake pad material becomes thinner
than the backing plate (approximately 1/16 inch/1.5 mm).

1

2

3

4

5

78

MAINTENANCE

Brakes

Brake Fluid

NOTICE: Brake fluid will damage decals, paint and some plastics.

Always wipe up spills immediately.

The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black. If
the sight glass is any color other than black, add brake fluid.

We recommend the use of Polaris DOT 4 high temperature brake fluid.
See page 105 for the part numbers of Polaris products.

WARNING

After opening a bottle of brake fluid, always discard any unused portion.
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rap­idly absorbs moisture from the air. The moisture causes the boiling tempera­ture of the brake fluid to drop, which can lead to early brake fade and the
possibility of accident or severe injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent slits allow for
diaphragm movement, and if they become plugged, movement of brake fluid
below the diaphragm may be restricted, altering brake function.

79

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.

During the bleeding procedure, keep the brake handle as level as possi­ble. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

7. After bleeding is complete, refill the reservoir to the proper level.

8. Reinstall the gasket and cover.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes,
which could cause an accident and lead to serious injury or death. Never
operate the vehicle with a spongy-feeling brake lever.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may
cause the brakes to lock, resulting in serious injury or death. Always add
brake fluid to the fill line as recommended.

80

MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following pro­cedure:

1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed two (2) inches (5.1 cm) below the mark
placed on the wall in step 4.

NOTE: Rider weight must be included on the seat.

5. Turn the adjustment nut, located inside the hood, just below the

headlamp opening. Turn the knob in or out as needed for proper
aim.

2 in. (5.1 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustment

Nut

81

MAINTENANCE

Lights

NOTE: Avoid touching a halogen bulb with bare fingers. Oil from skin

leaves a residue, causing a hot spot that will shorten the life of
the lamp. If fingers do touch the bulb, clean it with an alcohol­moistened towel.

Headlight Bulb Replacement

1. Pinch the ends of the spring (1)

together and lift until it releases
from the spring retainer.

2. Lift the spring carefully around

the wire harness (2) and flip it to
the outside of the housing.

3. With the wire harness attached

to the bulb (3), withdraw the
bulb from the housing.

4. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

5. Hold the new bulb by its metal base and install it into the wire har-

ness.

6. Insert the bulb into the housing. Carefully flip the spring back into

the housing, placing it around the wire harness.

7. Squeeze the spring together until it's over the spring retainer and

release.

8. Verify headlight aim. See page 80.

Taillight/Brakelight Replacement

1. Remove the screws (1) securing the

taillight housing (2).

2. Remove and replace the bulb (3).

3. Reassemble all components.

1

2

3

1

2

3

82

MAINTENANCE

Clutch System

Periodically inspect the clutch sheaves for damage, wear, or belt resi­due. To maintain optimum performance, clean with non-oil based clean­ers such as isopropyl alcohol.

NOTICE: The bushings in the weights and rollers of Polaris clutches are

made of a material that may be damaged if lubricated. Do not
lubricate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor­mance. Please see your Polaris dealer if you experience a decrease in
performance.

Clutch Center Distance

Refer to your Owner’s Manual Supplement for recommended center
distance for your machine. If adjustment is necessary, see your dealer.

WARNING

If you become aware of higher than normal clutch engagement or an unusual
vibration or shift pattern, see your dealer immediately. Do not operate the
machine until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized
Polaris dealer. Any unauthorized modifications to clutches, such as adding or
removing weights, will void the warranty.

83

MAINTENANCE

Clutch System

n Drive Belt Condition

Belt width and length must match the center distance of the clutches and
sheave width of the drive clutch. For this reason, Polaris recommends
that only O.E.M. belts be used. Other belts may match the dimensions,
but can drastically change the shift pattern, resulting in poor perfor­mance. See Belt Troubleshooting on page 107.

Periodically check the condition and tension of the drive belt, and
always carry a spare. Inspect the belt for signs of excessive wear: frayed
edges, missing cogs, cracks and excessive looseness. Replace the belt if
any of these conditions exist.

NOTE: A worn belt will continue to function, but will not deliver maxi-

mum performance. Always carry a spare belt in case of an
emergency.

For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.

84

MAINTENANCE

Clutch System

Drive Belt Removal

1. Stop the engine after operating in

a forward motion.

2. Turn the ignition key off. Wait for

the engine to stop completely.

3. Lock the parking brake (if

equipped).

4. Open the hood.

5. Remove the clutch guard retain-

ing pin and open the clutch
guard.

6. Firmly grasp the belt midway

between the clutches and pull
upward and rearward to remove. See illustration.

85

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back
the slack.

NOTE: To ensure satisfactory

belt life, install belts so
they operate in the
same direction of rota­tion by positioning the
identification numbers
so that you can read
them. If required, sepa­rate the sheaves as
outlined in the belt removal procedures.

2. Turn the driven clutch moveable sheave clockwise while pushing

inward and forcing the belt down between the sheaves.

3. Hold the belt down between

the sheaves and roll the bot­tom portion over the outer
clutch sheave. Work the belt
to the outer edge of the
sheave.

4. Close the clutch guard and

reinstall the retaining pin.

5. Close and secure the hood

and release the parking
brake.

86

MAINTENANCE

Clutch System

n Drive Belt Deflection

Measure belt deflection with
both clutches at rest and in
their full neutral position.

Place a straight edge on the
belt (1) and apply downward
pressure while measuring at
point 2. This measurement
should be 1 1/4 inches (32
mm).

Drive Belt Adjustment

Belt deflection should be adjusted without removing the clutch from the
jackshaft.

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as

needed.

NOTE: Turn the set screw in (clockwise) to increase the distance

between the sheaves and out (counterclockwise) to decrease
the distance.

3. Tighten the jam nut.

1

2

87

MAINTENANCE

Clutch System

To r q u e S t o p

Periodically check torque stop
clearance. With clutches in
proper alignment, the torque stop
clearance should be .010-.030
inch (.25-.75 mm) from the
engine case.

Adjust if necessary, and lock the
jam nut.

To o l K i t

A tool kit is included with each machine for emergency and routine
maintenance. Always keep the tool kit with the snowmobile.

Chain Tension

Maintain the proper chain tension as outlined on page 76.

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your
Polaris dealer.

.010-.030 in.

(.25-.75 mm)

88

MAINTENANCE

Tr ack

Track Inspection

1. Using a hoist, safely lift

and support the rear of the
snowmobile off the ground.

2. Rotate the track by hand to

check for possible damage.

3. Carefully examine the track

along the entire length of
each rod (+). Bend the
track to check for break­age.

4. Replace the track if any rod

damage is found.

WARNING

Broken track rods are a serious safety hazard. They can cause a rotating
track to come off the machine, which could cause serious injury or death.
Never operate with a damaged track. Never rotate a damaged track under
power.

+

89

MAINTENANCE

Tr ack

Track Lubrication

The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new rail slide can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.

NOTE: If excessive rail slide wear occurs due to poor snow conditions,

additional wheel kits are available. See your dealer for more
information.

NOTE: Track damage or failure caused by operation on ice or under

other poor lubrication conditions will void the track warranty.

WARNING

Operating with insufficient lubrication between the rail slide and track guide
clips can cause track failure, loss of vehicle control and loss of braking ability,
which can result in serious injury or death.

Avoid operating for extended periods on ice and other surfaces that have lit­tle or no snow for lubrication.

90

MAINTENANCE

Tr ack

Track Tension

Track adjustment is critical for proper handling. Always maintain cor­rect tension and alignment. Tension adjustments should be made only
after the track is warmed up and limber.

1. Turn the engine off.

2. Lift the rear of the machine and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track

at the distance specified (see chart) ahead of the center of the rear
idler wheel.

NOTE: Measure at the point where the weight is hanging.

4. Check for specified slack between the wear surface of the track clip

and the plastic rail slide.

WARNING

Moving parts can cut and crush body parts. When performing the checks and
adjustments recommended on the following pages, stay clear of all moving
parts. Never perform track measurement or adjustments with the engine run­ning.

WARNING

Improper track tension can cause serious damage to the snowmobile, which
can result in loss of vehicle control and serious injury or death. Always main­tain the track tension as specified.

Weight Measurement

Location

Measurement

10 lbs. (4.54 kg) 16 inches (40 cm) ahead of

rear idler shaft

3/4-1 inch (2-2.5 cm)

91

MAINTENANCE

Tr ack

Track Tension
If the track needs adjustment:

5. Loosen the rear idler

shaft bolt.

6. Loosen the locknuts.

7. Tighten or loosen the

track adjusting screws
as necessary to pro­vide equal adjustment
on both sides of the
track.

8. Repeat the measure-

ment on the other side
of the track.

NOTE: Check more fre-

quently when
machine is new.

9. Start the engine and slowly rotate the track at least five revolutions.

Let the track come to a stop (do not apply brakes).

10. Check track alignment (see page 92) and adjust as necessary.

11. Tighten the locknuts.

12. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).

Adjusting
Screw

Locknut

Slack
Measurement

Track

10 lbs. (4.54 kg)

Idler Shaft

Bolt

16 in. (40 cm)

92

MAINTENANCE

Tr ac k

n Track Alignment

Periodically check that the track is
centered and running evenly on the
slide rails. Misalignment will cause
excessive wear to the track and slide
rail.

1. Safely support the rear of the

machine with the track off the
ground.

2. Start the engine and apply a

small amount of throttle until
the track turns slowly at least
five complete revolutions. Stop
the engine and let the track
come to a stop (do not apply
brakes).

3. Inspect track alignment by looking through the track window to

make sure the rails are evenly spaced on each side. If the track runs
to the left, loosen the left locknut and tighten the left adjusting bolt.
If the track runs to the right, loosen the right locknut and tighten the
right adjusting bolt.

4. After adjustments are complete, tighten locknuts and torque idler

shaft bolts to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

Rails

93

MAINTENANCE

Steering System

Steering Inspection

Each week, or before a long ride, check fasteners and tighten if neces­sary. Specific fasteners that should be checked are marked with a + in
the illustration.

+

+

+

+

+

+

94

MAINTENANCE

Steering System

Ski Alignment

With the handlebars in a straight-ahead position, and with vehicle
weight compressing the suspension, measure from the straight edge of
the skis at the center of the ski mounting bolt. The measurement
between the skis at point X should be 1/8-1/4 inch (3-6 mm) greater than
at point Y.

NOTE: If the skis are misaligned, we recommend that your dealer cor-

rect the alignment, since camber adjustment may also be
affected.

WARNING

Improper ski alignment or adjustment may cause loss of steering control,
resulting in serious injury or death. Do not attempt to change the ski align­ment or camber adjustment. See your Polaris dealer.

X

Y

10 in. (25.4 cm)

10 in. (25.4 cm)

95

MAINTENANCE

Steering System

n Ski Skags

Check skags weekly to maintain positive steering characteristics. Skags
must be replaced when worn to half their original diameter.

NOTE: Carbide skags must be replaced if any abnormal wear or chip-

ping is found.

Skag Replacement

1. Raise and support the front of the machine so the skis are approxi-

mately 6I (15.2 cm) from the ground.

2. Remove the attaching hardware and pry the skag downward.

3. Remove the rear end of the skag.

4. Remove the front end of the skag.

5. Reverse the steps to install a skag.

WARNING

Worn skis and/or skags will adversely affect handling. Loss of vehicle control
may result, causing serious injury or death.

See your dealer’s studding chart for recommended skags. If you install
longer or more aggressive carbide skags than the original equipment, it may
also be necessary to add track studs to maintain proper vehicle control while
turning on hard-packed snow or ice.

96

MAINTENANCE

Suspension Maintenance

n Rail Slide Wear

For ease of inspection, all
Polaris rail slides have a
wear limit indicator groove
to indicate the minimum per­missible slide thickness.
Replace the rail slides if they
are worn to the top of the
groove at any point along
their length. Failure to do so
may result in permanent
damage to the track or rails.

Suspension Inspections

Loose nuts and bolts can reduce your snowmobile’s reliability and cause
needless repairs and down time. Before beginning any snowmobile trip,
a visual inspection will uncover potential problems. Check the follow­ing items on a weekly basis or before any long trip:

n Check suspension mounting bolts for tightness.

n Check rear idler wheel bolts for tightness. See page 91.

n Check rear idler adjusting bolt locknuts for tightness.

n Check front torque arm limiter strap condition.

n Check rail slide condition.

n Check track tension. See page 90.

n Lubricate/grease all suspension components. See page 66.

n Check ski runner/skag condition. See page 95.

n Check ski spindle bolts for tightness.

n Check tie rod end nuts for tightness.

Replace when

worn to top of

groove

Minimum

Thickness

97

MAINTENANCE

Battery

Battery Fluid

A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. The fluid level
should be kept between the upper and
lower level marks.

Add only distilled water. Tap water
contains minerals that are harmful to
a battery.

WARNING

Battery electrolyte is poisonous. It contains acid! Serious burns can result
from contact with the skin, eyes, or clothing. If contact occurs, seek immedi­ate medical attention.

KEEP OUT OF REACH OF CHILDREN.

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Call physician immedi­ately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, open flames, cigarettes,
etc. away. Ventilate when charging or using in closed space. Always shield
eyes when working near batteries.

Upper Mark

Lower
Mark