Polaris 500 XC SP, 340 LX 2007, 550 LX 2007, Supersport 2007, 500 XC SP 2007 Owner's Manual

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone] Fax [phone]
Part No. 9920437 Rev 02
Printed in USA

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 enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introduc­tions, upcoming events, career opportunities and more.

Here at Polaris 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.

RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2006 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.
2007 340 LX/550 LX/Supersport/500 XC SP Owner's Manual
P/N 9920437

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 45

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 125

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 126

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 142

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

4

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: ___________________________________________________________

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.

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.

5

INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam­paign. We encourage governments 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

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, on your vehicle or in this manual, alerts you to the
potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious
injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

7

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 74
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 or riding as a passenger.
They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to
ensure operator safety. Make sure your snowmobile is in excellent operating
condition at all times. Always 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.

8

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.

9

SAFETY

Operator Safety

Riding Position

Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, 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.

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 20.

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

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.

WARNING

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

E

4

051039

0006.31

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:

• 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

11

SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have an
increased risk of loss of control, which could result in serious injury or
death.

Rider Capacity

Your Polaris snowmobile is designed for a single rider only. Do not
carry a passenger.

Excessive Speed

Always observe all laws governing snowmobile operation and speed
limits. 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 injury or death.
Always reduce speed when driving at night or in inclement weather.

12

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. You may drown if you break through the ice. Avoid travelling
on frozen bodies of water.

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.

RR

13

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 either the
American Avalanche Association online at www.americanavalancheas­sociation.org or the U.S. Forest Service National Avalanche Center at
www.avalanche.org.

14

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, remove ice and snow build-up that may be obstructing
the steering linkage.

Driving on Slippery Surfaces

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

Never attempt an abrupt change of direction when operating on slippery sur­faces. Proceed slowly and use extra caution.

Driving on ice or hard-packed snow reduces steering and braking control,
which may result in loss of control and serious injury or death. Slow down
and use extra caution when operating on slippery surfaces.

15

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.

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.

16

SAFETY

Operator Safety

Driving in Hilly Terrain

Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep 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.

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.

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.

17

SAFETY

Operator 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 injury or damage to the engine.

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.

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 safety guard by removing it.

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.

Maneuverability

While much control and maneuverability is achieved through the steer­ing system and skis, maximum control is achieved by the shifting of
your body weight. Maneuverability will change for lighter operators or
machines designed to carry a load.

18

SAFETY

Operator Safety

Inadequate Snow Conditions

Moveable hood closures are included on some Polaris snowmobiles.
They are normally left open and are located on the front upper and lower
hood openings. If operating in deep snow or in extreme cold conditions
(below -20_ F), Polaris recommends closing the upper hood closure.

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.

WARNING

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

CAUTION

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

19

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

• 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.

20

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (_F)

WINDCHILL 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 - -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.

21

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 plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself -- see your dealer.

Airbox Warning

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

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

Pressure Cap Warning

This warning decal is found under the hood on the pressure cap of appli­cable liquid cooled models:

Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI

22

SAFETY

Safety Decals and Locations

Track Warning

The track 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.

"No Passenger" Warning

Some snowmobiles are designed
for the operator only, while others
are designed for the operator and
one passenger. A warning decal
on the console indicates whether
it's designed for the operator only
(1-Up) or the operator and a pas­senger (2-Up).

Decal text found on 1-up models:

WARNING

This vehicle is designed for
operator only.

“NO PASSENGER”

+

+

23

SAFETY

Safety Decals and Locations

Reverse Warning

Some Polaris snowmobiles are
equipped with reverse. These
models have a reverse warning
decal on the lower dash.:

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.

If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH con­trol to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

• Elevation setting (above 6000 feet): push and hold for longer than 5
seconds to set. Let go of button at desired setting-fast flash for high
elevation, slower flash for low. Setting will remain until changed.

Operation Warning

The operation warning decal is located on the console.

+

24

SAFETY

Safety Decals and Locations

Operation Warning

The operation warning decal is located on the console of all Polaris
snowmobiles:

• 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 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.

25

FEATURES

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Storage Compartment

7. Taillights

8. Rear Bumper

9. Snow Flap

10. Track

11. Suspension

12. Ski

13. Nosepan

14. Front Bumper

5

10

2

3

4

11

9

12

13

14

1

8

7

6

26

FEATURES

Some Polaris snowmobiles are equipped with special features such as a
reverse indicator light, electronic fuel gauge, temperature light and elec­tric shock control gauge. Not all models come with these features. Refer
to your Owner's Manual Supplement for the features on your machine.

1

2

3

5

6

7

8

9

4

10

27

FEATURES

1. Fuel Filler Cap

2. Ignition Switch

3. Brake Lever

4. Speedometer

5. Tachometer

6. Engine Stop Switch

7. Throttle Control

8. Hood Hold Down Straps

9. Recoil Starter Handle

10. Choke

11. Headlight Dimmer Switch

12. Parking Brake

13. Handlebar Grip Warmer Switch

14. Thumbwarmer Switch

15. Electronic Reverse Button

16. Electronic Shock Control Button

12

16

15

14

13

11

28

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.

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

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Shock damping (if equipped
with Indy Select shocks)

• Front shock spring preload

• Optional springs

• Toe (ski alignment) (see
page 114)

• Camber (see your dealer)

2

3

4

1

29

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

For the best ride, the suspension should be adjusted to use the full travel
of the shocks with occasional light bottoming. To determine if your
machine is using full travel, push the jounce bumper down on the shock
rod until it contacts the body and test ride the machine. The bumper will
move up on the rod in relation to the amount of travel that was used dur­ing the ride. If the travel is full, the bumper will be seated at the top of
the rod.

Shock Components

The front springs can be changed if spring
preload alone isn't sufficient and further
adjustment is desired to control suspension
stiffness. See your Polaris dealer for more
information.

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
114 to check alignment. If the skis are misaligned, see your dealer, as the
camber adjustment may also be affected.

2

3

4

5

1

30

THE PERFECT FIT

Front Suspension Adjustments

Shock Damping

Adjustments to the compression stiff­ness of Indy Select shocks can be
made by turning the adjustment screw
located near the base of the shock (+).
This adjustment is the easiest to per­form and it should be considered first.
A clockwise adjustment will increase
stiffness in both styles of shock, but
there are some differences.

Indy Select Shock

The factory setting for this shock is the softest position, with the adjust­ing screw all the way out (counterclockwise). If bottoming occurs, the
Indy Select feature should be used to achieve the desired ride. The
shocks have a wide range of adjustment capability. By turning the screw
clockwise, the compression of the shock increases, stiffening the ride.
When adjusting these shocks, we recommend that you turn the screw
only 1/4 turn at a time, then test ride. Always adjust both shocks equally.

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. See your
Polaris dealer for more information.

+

31

THE PERFECT FIT

Front Suspension Adjustments

Spring Preload

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

To increase front shock spring preload,
grasp the spring and turn it to the right.
Turn it to the left to decrease preload.

Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch of
preload beyond the factory settings, and
ensure that both sides are adjusted the
same. When decreasing preload, make sure at least two turns of preload
are holding the spring between the retainer on top of the shock and the
threaded spring preload adjuster nut on the shock body.

NOTE: Not all models have shocks with thread adjustable spring pre-

load. See your dealer for more information.

CAUTION

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

Low

Preload

High

Preload

32

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 snowcross racing would provide a
very stiff ride on the trail. A suspension set up for trail riding would bot­tom out harshly on a snowcross 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.

33

THE PERFECT FIT

Rear Suspension Adjustments

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 setup. 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

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 78.

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 110.

34

THE PERFECT FIT

EDGE Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

Take the first measurement with
no rider and with the rear suspen­sion at full extension.

NOTE: The rear bumper may

need to be lifted upward
slightly to fully extend the
rear suspension.

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

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

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

X

Y

35

THE PERFECT FIT

EDGE Rear Suspension Adjustments

Torsion Spring Tension

To adjust rear torsion spring tension, rotate the three-position cam using
the engine spark plug tool. Different rate torsion springs are available if
a firmer ride is desired. See your dealer for more information.

Soft Tension Medium Tension Firm Tension

36

THE PERFECT FIT

EDGE Rear Suspension Adjustments

Rear Shocks

Indy Select Rear Shock

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

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

If bottoming continues after the screw has been turned fully clockwise,
the torsion spring should be adjusted (see page 35). Return the screw to
its original starting position after the torsion spring has been tightened.

Adjustment Screw

37

THE PERFECT FIT

EDGE Rear Suspension Adjustments

Suspension Coupling

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

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

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

When hitting a bump, the front torque arm starts to compress. The FRSS
links that movement to the rear torque arm, causing it to compress and
raise the rear suspension up as one, allowing the suspension to hit the
bump only once and reducing kickback.

The factory setting is usually adequate for all riders and conditions.

38

THE PERFECT FIT

EDGE Rear Suspension Adjustments

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

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

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

Rear Rear Scissor Stop (RRSS) - Attributes

Moving the RRSS to a higher position will have the following effects on
the suspension:

• Reduced weight transfer.

• Improved chatter bump ride.

• Improved cornering performance.

39

THE PERFECT FIT

EDGE Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling
weight transfer during acceleration
is by adjusting the rear rear scissor
stop (RRSS). The factory setting is
the best for most trail riding condi­tions.

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

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

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

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

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

NOTE: Your dealer can help you

with initial setup and addi­tional setup instructions to
help you achieve your opti­mum ride.

Medium/High

Stock

Scissor
Stop
To o l

Rearward Upper

40

THE PERFECT FIT

Handlebar Adjustments

Handlebar Angle

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

1. Remove the handlebar

cover (1) to expose the
handlebar and the four
adjuster block bolts (2).

2. Using a 7/16I (11 mm)

wrench, loosen the four
nuts (3) on the bottom of
the adjuster block (turn
handlebar to left or right
for access to back nuts).

NOTE: If necessary, pry the

blocks apart with a
screwdriver.

3. Adjust the handlebar to the desired height. Be sure handlebars,

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

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

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

5. Reinstall the handlebar cover.

1

3

2

41

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies, 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.

42

THE PERFECT FIT

Traction Products

Studs

Before equipping your machine with traction products, be aware of the
laws in your area pertaining to the use of traction products. See your
dealer about installing studs and/or carbides. Many tracks with deep lug
designs cannot be studded, but your dealer will be able to offer advice
and assistance.

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

See your dealer about installing studs and/or carbides.

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

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

CAUTION

Always install wear strips before installing studs. Failure to install wear strips
may result in cooler or tunnel damage. See page 44.

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

Use of studs longer than the recommended length on machines equipped
with center coolers will result in center cooler damage or damage to the tun­nel.

CAUTION

Aggressive studding patterns may require grinding protruding stud bolts flush
to prevent idler wheel damage. Maintain track tension on studded tracks on
the tight side of the spec to prevent heat exchanger damage. The center of

the stud must be at least 1 1/8

I (2.86 cm) from the outside edge of the track.

43

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. Use carbide skags with studded tracks
to help maintain proper vehicle steering and control. See page 43.

If your machine has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.

Inspect skags and studs frequently. Worn studs or skags may reduce
steering and braking control on hard-packed snow and ice. Replace
worn studs and 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.

44

THE PERFECT FIT

Traction Products

Wear Strips

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

Some models are manufactured with tunnel wear strips or wear strip
coolers installed. Wear strips are designed for a specific stud length. See

your dealer's studding chart for recommended traction accessories.

Components (viewed from rear of track)

1. Top of tunnel

2. Wear strip

3. Track

4. Wear strip mounting holes

CAUTION

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

1

2

3

4

45

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 102, 105

Steering System 50

Recoil Rope 51

Coolant Level 92

Parking Brake Lock/Brake Lever/Brake System 47, 48, 95

Auxiliary Shut-Off Switch (Engine Stop Switch) 52

Ignition Switch 52

Taillight/Brakelight/Headlight 52

Suspension Mounting Bolts 116

Skags (Wear Bars) 43

Ski Saddle and Spindle Bolts 116

Hood Straps/Latches 51

Seat Latches (if equipped) N/A

Throttle Lever/Safety Switch 63, 46

Rear Wheel Idler Bolts 111

Tether Switch/Strap 52

Track Alignment/Condition 50, 112

Rail Slide Condition 116

Chaincase Oil Level 82

Injection Oil Level 60

46

PRE-RIDE INSPECTIONS

Before Starting the Engine

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.

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated.
See page 63.

WARNING

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

47

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Brakes

Always check the following items for proper operation before starting
the engine.

Brake Lever Travel

Squeeze the brake lever. It
should move no closer to
the handgrip than 1/2I
(1.3 cm). A smaller dis­tance indicates low brake
fluid level or air in the
hydraulic system. Refer to
the brake bleeding infor­mation on page 97 or see
your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 96.

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.

1/2I (1.3 cm)

48

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Use the parking 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 (if equipped)

3. Master Cylinder Reser-

voir/ 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 on the console will light up if the parking brake lever
lock is set while the engine is running. It will also be lit 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.

1

2

3

4

49

PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

Lock Release

To release the lock, squeeze the brake lever tightly and release it. The
lock will return to the unlock 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.

50

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

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, remove ice and snow build-up that may be obstructing
the steering linkage.

n Track

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

lubrication conditions voids the track warranty.

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

Operating the snowmobile with a damaged track increases the possibility of
track failure, which could cause loss of control resulting in serious injury or
death. Always inspect the track for damage before using the vehicle.

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

51

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 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).

52

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch

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

n Ignition Switch

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

n Tet her Sw i tch

If your machine has a tether switch, remove the tether from the switch to
make sure the engine stops immediately.

n Lighting

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

n Mirror Adjustment (if equipped)

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

n Operating Area

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

53

OPERATION

Starting the Engine

1. Turn the fuel valve on. See page

57.

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 ON. 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.

6. If not equipped with electric start, grasp the recoil rope 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 ON position.

WARNING

Before starting the engine, always refer to all safety warnings pertaining to
snowmobile operation. Never start your snowmobile without checking all
components to be sure of proper operation. See Before Starting the Engine
beginning on page 46.

WARNING

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

CHOKE TOGGLE

POSITIONS

OFF

HALF ON

FULL ON

54

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

CAUTION

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.

55

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 60.

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection
systems. On Polaris snowmobiles equipped with a variable exhaust sys­tem (VES), Polaris highly recommends the use of only VES II 2 Cycle
Oil. See the table below for additional oil recommendations. See page
125 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

CAUTION

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.

Engine

Style

Premium

2-Cycle

Premium Gold

2-Cycle

VES II

2-Cycle

Fan Cooled Good Better N/A

Liquid Cooled Good Better N/A

Liquid Cooled w/VES Good Better Best

CAUTION

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.

56

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
about 4I (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

to loosen snow and ice.

WARNING

A loose track or flying debris could cause serious 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. Use a stable rear sup­port.

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.

57

OPERATION

Fuel Valve

Turn the fuel valve clockwise
to OFF to shut off the fuel
supply. Turn the valve
counter-clockwise to ON to
turn the fuel supply on.

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

• Do not overfill the tank. Do not fill 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.

OFF

ON

58

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 across the country, so
we encourage the use of premium fuel when possible. Always use the
premium fuel switch when using premium fuel. Do not use lower than
87 octane fuel. Do not use fuel containing more than 10% ethanol

(including E85)

NOTE: Some engines require premium fuel. See your Owner’s Manual

Supplement.

Premium Fuel Switch

If your Polaris snowmobile is equipped
with a key function to adjust the timing
on the machine as you change fuels, it's
very important to the life of your
engine that you use this feature.

When using fuels with a pump-posted
octane rating of 91 or higher, turn the
key switch to ON/PREM. When the
engine is started, a yellow Premium
Fuel light illuminates on the instrument
panel. When the key is in this position,
the fuel must be a minimum of 91
octane. Return the key switch to the
ON/REG position when not using pre­mium fuel.

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

CAUTION

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.

OFF

ON/
PREM

ON/REG

OFF

ON/
PREM

ON/REG

Premium Fuel Setting

Regular Fuel Setting

59

OPERATION

Fuel

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 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or additives
containing methanol. Polaris also recommends the use of Carbon Clean
Plus. See page 125 for the part numbers of Polaris products.

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

CAUTION

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

60

OPERATION

Oil

n Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile.

n Low Oil Level

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

Always check the oil level when refueling. Maintain the oil level above
the tank's low level line. When the oil reaches the low level mark, add
one U.S. quart of recommended oil. See page 55 for oil recommenda­tions.

NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil

flow. See your Polaris dealer for recommended replacement
parts.

CAUTION

Operating the snowmobile without adequate engine lubrication can result in
serious engine damage. Always check the oil level when refueling. Add oil as
needed.

61

OPERATION

Carburetion

Proper carburetor adjustment is critical. A lean mixture (too much air,
too little fuel) may result in piston burning, bearing failure, or complete
engine failure. A rich mixture (too much fuel, too little air) may foul
plugs and cause generally poor engine performance.

A lean mixture may be caused by things like fuel line restrictions, for­eign matter in the carburetor or clogged fuel filters. A rich mixture may
be caused by snow build-up on 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.

62

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.

The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and
ambient temperatures between -10 to +10 degrees F. (-23 to -12 degrees
C). 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. See page 88 for more information.

NOTE: 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.

CAUTION

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 in your Owner's Manual Supple­ment.

63

OPERATION

n Engine Stop Switch

Push down on the engine
stop switch (+) to
ground out the ignition
and stop the engine
quickly. Pull the switch
up to the ON position to
allow restarting.

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.

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.

+

64

OPERATION

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 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 freeplay 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.

65

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 63 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

Tether Switch (Option) Interrupts ignition circuit All

66

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. On non-electric-start models, if the recoil starter
system fails, an emergency start strap is provided in the kit.

1. Open the hood.

2. Open the clutch guard.

3. Push on the inner sheave of
the clutch and rotate clock­wise slightly to relieve belt
tension.

4. Starting at one of the tower
struts, wind the strap counter­clockwise around the clutch
as shown.

5. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine. Repeat until the engine starts.

6. Close the clutch guard.

7. Close and secure the hood.

WARNING

Serious injury can result from wrapping the start strap around your hand
while using the emergency starting procedure. DO NOT wrap the start strap
around your hand. Keep all bystanders and loose clothing away from the
snowmobile when using the emergency starting procedure.

67

OPERATION

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.

68

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Electronic reverse will activate only if the engine RPM is below 4000. If
your machine is running at an altitude of over 6000 feet, adjust the igni­tion setting as described below. Always make sure the vehicle is stopped
and the engine is running at idle before shifting to reverse.

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your vehicle is clear.

3. Push the yellow reverse button (+)

on the left-hand control for one sec­ond, then release. The engine will
automatically reduce RPM and start
a reverse rotation. A flashing
reverse light on the instrument
panel will indicate that the machine
is in reverse.

4. Apply the throttle slowly to make
sure the machine is in reverse.

NOTE: The maximum engine RPM will be 6000 when in reverse.

NOTE: If the engine stops running, the snowmobile will be in forward

gear when it's restarted.

+

69

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The
engine will slow and begin to rotate forward. The light on the
instrument panel will shut off.

3. Apply the throttle slowly to make sure the machine is in forward.

Altitude Setting

At higher altitudes (above 6000 feet), the engine will require a different
ignition setting to improve the success of the reverse system. To set for a
higher altitude, start the engine and hold the button down until the light
on the instrument panel flashes rapidly, then release the button.

To set the reverse for lower elevations, continue holding the button
down until the reverse indicator light blinks slowly. Once set, it's stored
in memory until changed, whether the machine is running or not.

70

OPERATION

Daily Storage

At the end of each ride, park the snow­mobile on a level surface and support it
at the rear with an appropriate track
stand. The track should be suspended
approximately 4I (10 cm) off the
ground.

Remove the key and cover the machine.

71

OPERATION

To w i n g

For your safety, do not attempt to use a 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 someone ride on the
towed snowmobile to operate the brake and steering when necessary.

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.

CAUTION

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.

72

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. The emission control system designation
per SAE J1930 is EM. 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.

73

MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty on
page 140, and read the maintenance section of your owner's manual.
You are responsible for ensuring that the specified maintenance is per­formed, including the emission-related maintenance outlined in these
sections of the manual.

You must inspect the air intake system on your snowmobile prior to
each use (including the airbox foam filter and hood foam filters) and
clean these components as necessary. Polaris considers the specified
maintenance for the spark plugs, oil changes, air intake system and
exhaust valves to be critical emission-related maintenance. The speci­fied maintenance for the fuel filter is recommended additional emission­related maintenance. Any qualified repair shop or qualified person may
maintain, replace, or repair the emission control devices or systems on
your snowmobile. Polaris recommends that you contact an authorized
Polaris dealer to perform any service that may be necessary.

74

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 142.

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.

CAUTION

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.

75

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 Alignment Offset
(without belt)

101 II I

Drive Belt Condition 102 II II

Clutches (disassemble) 100 CCC

Belt Tension -- II II

Clutch Sheaves 100 II II

ENGINE/COOLING

Engine Mounts -- IIII

Recoil Rope -- IIII

Engine Mounting Plate -- II I

Engine Torque Stop 106 II II

Cylinder Head Bolts -- II I

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- II I

VES System -- CCC I

Coolant Level 92 IIRI

Water Pump Drive Belt 102 II I

Coolant Hose -- IIII

Heat Exchangers -- II I I I

Coolant Circulation -- II I

Coolant Leaks -- II II

Spark Plug Condition 83 II IRI

Exhaust Pipe 89 II

Exhaust Retaining
Springs

89 II II

76

MAINTENANCE

Periodic Maintenance Interval Table

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 -- II II

Hose Condition -- II II

Fluid Leaks -- II II

Brake Pads 95 II II

Brake Disc -- II II

Parking Brakes 48 II II

Brake System 47, 95 I

Brake Fluid 96 R

FUEL MANAGEMENT

Pilot Air Screws -- II I

Carburetor
(synchronize)

88 II I

Idle RPM -- II I

Throttle Lever 46 II I I I

Oil Pump Lever
(synchronize)

-- II I

Throttle Cable 81 LL L

Choke Cable 81 LL L

Choke 81 II I

Vent Lines -- II II

Throttle Position
Sensor

-- II I

Fuel Lines 85 II I I I

Fuel Filter 85 RR

Oil Filter 86 RR

Oil Lines -- III

Oil Change -- RR

Air Box -- II I I I

Drain and Water Traps 87 II I

ELECTRICAL

Auxiliary Shut-Off
Switch

52 II I I I

Throttle Safety Switch 63 II I I I

Ignition Switch -- II I I I

Taillight 52 II I I I

Brakelight 52 III I I

Headlight 52 II I I I

77

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

Ski Toe Alignment -- II I

Suspension Mounting
Bolts

-- II I I I

Steering Fasteners -- II I IC

Rear Suspension Fas­teners

-- II I I I

Suspension Shock Oil -- II II

Cooling Fins and
Shroud

-- II II

Drive Shaft Bearing 80 LL L I

Jackshaft Bearings 118 LL L I

Skags (Wear Bars) 43 II I I I

Ski Saddle/Spindle
Bolts

-- II I I I

Ski Pivots 78 LLL L I

Ski Spindle 78 LLL L I

Steering Arm(s) -- I

Upper / Lower Steering
Post Support Bracket

78 LL L L I

Drive Chain Tension 94 II I I I

Hood Latches 51 II I I I

Battery Fluid Level 121 II I I I

Rear Wheel Idler Bolts 111 II I I I

Idler Bolt Jam Nut 111 II I I I

Rear Suspension Pivot
Shafts

78 LL L

Camber Alignment -- II I

Radius Rod Bushings -- I

Handlebar Centering -- I

Tether Switch and Strap 52 II I I I

Track Alignment 112 III I I

Track Tension 110 II I I I

Front Limiter Strap -- II I I I

Rail Slide Condition 116 I

Chaincase Oil 82 II IRI

Gearcase Oil -- II IRI

78

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 125 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).

+

+

+

+

+

79

MAINTENANCE

Lubrication

EDGE Rear Suspension

+

+

+

+

+

80

MAINTENANCE

Lubrication

Jackshaft Bearing

Loosen the driven clutch retaining
bolt and pull the clutch outward to
expose the bearing and grease fit­ting. Inject grease into the grease
fitting in the flangette until grease
purges from inside or outside the
bearing seal (may take only two
pumps). Push the clutch back onto
the shaft and replace the clutch
retaining bolt. Torque to 18 ft. lbs.
(24.4 Nm).

Driveshaft Bearing

Inject grease into the fitting on the
speedometer sensor housing until
grease purges from the seal on the
inside of the tunnel. This should
take approximately two pumps. Do
not use more than four pumps.

+

+

+

81

MAINTENANCE

Lubrication

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 Choke 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.

+

+

82

MAINTENANCE

Lubrication

n Chaincase Oil

Check the chaincase oil level at the intervals outlined in the mainte­nance charts beginning on page 74. Change the chaincase oil after the
first 500 miles (800 km), then every 1000 miles (1600 km) or season­ally.

Maintain the oil level between the “safe” marks on the dipstick. Clean
the magnetic plug on the dipstick whenever checking or changing oil.

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See
page 125 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on
a level surface.

2. Remove the dipstick (1)

and view the oil level
on the dipstick.

3. Add the recommended

oil as needed. Do not
overfill.

4. Clean the magnetic

plug (2).

5. Reinstall the dipstick.

1

2

83

MAINTENANCE

Spark Plugs

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. Refer to your Owner's
Manual Supplement for the specific spark plug to be used in your
machine.

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 the Owner's Manual Supplement or see your
dealer.

CAUTION

Using non-recommended spark plugs can result in serious engine damage. 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. See your
Owner’s Manual Supplement.

• Use recommended spark plugs with the proper gap.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

• Always carry spare spark plugs.

WARNING

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

84

MAINTENANCE

Spark Plugs

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
carburetor/throttle body 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.

4. Torque the spark plug to specification.

5. Reinstall the spark plug cap.

85

MAINTENANCE

Intake Filters

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

Fuel Filter/Fuel Lines

See your Polaris dealer for replacement of the in-tank fuel filter every
1000 miles (or annually).

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.

CAUTION

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.

CAUTION

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.

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MAINTENANCE

Oil Filter

The oil filter should be
changed annually or every
1000 miles (1600 km).
Inspect oil line condition at
1000 miles (1600 km). Polaris
oil filters are specially
designed for use on Polaris
products. We strongly recom­mend the use of only Polaris
replacement parts. See page
55 for oil recommendations.

EDGE models use an oil filter that's built into the oil sending unit
located in the bottom of the oil tank. After changing the oil filter, bleed
the oil injection system of all trapped air. See your dealer for instruc­tions, or have your dealer perform the filter change and bleeding opera­tion for you.

NOTE: The direction of the arrow indicates the direction of flow through

the filters.

87

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 at least every 2000 miles (3200
km) and inspected for contamination.

Plug Cleaning Procedure

1. Turn the fuel tank supply valve off.

2. Position a container or shop towels to
catch the contaminated gasoline.

3. Slide the clamp (1) away from the drain
plug (2) 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 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 57.

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88

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.

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

CAUTION

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.

89

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000
miles (3200 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.

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.

90

MAINTENANCE

Cooling System

The cooling system on liquid cooled models consists of the following
major components:

• Coolant bottle

• Water pump

• Cylinders

•Heads

• Inlet and outlet manifolds

• Pressure cap

• Heat exchangers

91

MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of
ethylene-glycol and distilled water, which will provide adequate freeze
protection under most conditions. If the vehicle will be stored or oper­ated at extremely low temperatures, greater protection may be required.
Please see your Polaris dealer.

When adding or changing coolant, Polaris recommends using Premium
60/40 anti-freeze coolant, which is already premixed and ready to use.
Do not dilute with water. Never exceed a 60% antifreeze/40% water
mixture. See page 125 for the part numbers of Polaris products.

NOTE: Never add tap water to the cooling system. Minerals cause

deposits and may react adversely with the metals in the engine
and cooling system.

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by a switch in the
engine cooling system on liquid cooled models. If the engine coolant
reaches a certain temperature, the switch completes a circuit that turns
the light on. If you must drive your machine after the high temperature
indicator light has come on, drive slowly and stop frequently to allow
the engine to cool down. See your dealer.

92

MAINTENANCE

Cooling System

n Coolant Level

The engine coolant level is controlled by the recovery system. The
recovery system components are:

• Coolant bottle or overflow tank

• Engine filler neck

• Pressure cap (on some models)

• Connecting hoses

Always maintain the coolant level between the minimum and maximum
marks on the coolant bottle (when engine is cold) to prevent overheating
and serious engine damage.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine,
drain the system completely every two years and add a fresh mixture of
antifreeze and distilled water. This service must be performed when the
engine is cold. Ask your Polaris dealer to check the coolant when he
performs the fall tune-up on your snowmobile.

CAUTION

Operating the snowmobile with insufficient coolant will result in overheating
and serious engine damage. Always maintain the coolant level as recom­mended.

93

MAINTENANCE

Cooling System

Bleeding the Cooling System

Use of a non-standard pressure cap will not allow the recovery system to
function properly. If the pressure cap needs replacement, contact your
dealer for the correct part.

Perform the bleeding procedure when the engine is cold.

1. Remove the pressure cap and fill the coolant bottle with properly

mixed coolant to the maximum mark.

2. Elevate the front end of the machine slightly to aid in bleeding of
the heat exchangers.

3. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.

4. Add coolant to the coolant bottle to the maximum mark.

5. Start the engine and run at a fast idle for two to three minutes.
Loosen the bleed screw occasionally to purge any trapped air.

6. Stop the engine and check the coolant bottle level. Fill as required.

7. Feel the heat exchangers under the running boards. If the system is
bled properly, they'll be warm to the touch. If they're not, repeat step

5. Lift the front of the machine slightly to assist in the bleeding.

8. Replace the pressure cap and carefully lower the front end of the
machine.

WARNING

Steam and hot liquids will cause serious burns to your skin. Never bleed the
cooling system or remove the pressure cap when the engine is warm or hot.

CAUTION

If coolant flow becomes restricted or plugged, coolant loss, air lock or engine
damage may result. Most cooling systems are equipped with a filter that
should be periodically inspected or replaced.

94

MAINTENANCE

Drive Chain Tension

Check drive chain tension
weekly and before each long trip.
To obtain correct chain tension:

1. Rotate the driven clutch
counterclockwise to move all
chain slack to the tensioner
side. Lock the brake lever
lock, or have an assistant
hold the brake lever firmly.

2. Loosen the adjuster bolt jam

nut (1).

3. Finger tighten the adjuster

bolt (2) until it can no longer
be adjusted by hand, then
back off 1/4 turn.

4. Tighten the jam nut while

holding the adjuster bolt.
Torque to 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

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95

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 47.

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

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance
develops, bring the machine to an authorized Polaris dealer for inspec­tion and adjustment.

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace
when thickness is less than
1/16I/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

I).

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96

MAINTENANCE

Brakes

Brake Fluid

On some models, 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.

On all other models, frequently check the reservoir to be sure it contains
the correct amount of fluid. To add fluid, remove the master cylinder
reservoir cover. Add the recommended brake fluid to bring the level up
to the top of the fluid level mark on the inside of the reservoir.

Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 125 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 serious 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.

CAUTION

Brake fluid will damage decals, paint and some plastics. Always wipe up
spills immediately.

97

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 the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16I (.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.
See page 96.

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.