Polaris 440 IQ User Manual

WARNING
Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S 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) T echnician.
Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. B e 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!
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POLARIS and POLARIS THE WAY OUT are registered trademarks 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 440 IQ Owner’s Manual P/N 9920432
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TABLE OF CONTENTS
Introduction 4...............................
This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.
Safety 7.....................................
This section describes safe vehicle operation and identifies warning decals and their locations.
Features and Controls 24.....................
This section illustrates 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 42......................
This section explains procedures that must be performed before riding.
Operation 48.................................
This section explains proper engine break-in, operation of features and operating procedures.
Maintenance 59..............................
This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance.
Polaris Products 99..........................
Troubleshooting 100.........................
This section is a quick reference guide to solving problems.
Warranty 105................................
Maintenance Record 1 11......................
Index 1 14....................................
3
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold.
Some of the illustrations and photos used in this manual are general representations. Your model may differ.
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.
4
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.
Noise Level
One of the most publicized issues about snowmobiles i s 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.
5
INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile’s identification numbers in the spaces provided.
Vehicle Model Number:
Tunnel VIN: (lower right side of the tunnel)
Engine Serial Number: (right front side of engine crankcase)
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when t hese 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.
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SAFETY
Operator Safety
Follow the recommended maintenance program outlined beginning on page 59 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.
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.
WARNING
Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay 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.
Stay Clear of Engine
Never attempt adjustments with the engine running. Stop the engine, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.
Riding Position
Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under most 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.
WARNING
Improper riding position may reduce control and could result in serious injury or death. Always be properly seated and in position to control your vehicle.
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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:
SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner’s Manual SFirst Aid Kit
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 19.
WARNING
Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.
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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
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.
Always observe all state and local 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 t raveling 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.
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 t o a stop in the distance illuminated by the headlight.
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SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to distinguish.
Make sure the way is clear before crossing railroads and other roads and highways. The noise of your machine will drown out the sound of approaching vehicles. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.
Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local residents or authorities for general information on conditions when traveling on l akes and streams that are strange to you. Before riding your machine on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. You may drown if you and the snowmobile break through the ice.
When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain:
S Take an avalanche class S Travel with experienced people S Travel on designated trails S 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 t hat 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.
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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING
Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
Driving on Slippery Surfaces
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.
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.
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SAFETY
Operator Safety
Driving in Hilly Terrain
WARNING
Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.
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.
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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.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the machine i nto motion, but always operate within safety limits.
Maneuverability
While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by t he shifting of your body weight. Maneuverability will change for lighter operators or machines designed to carry a load.
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SAFETY
Operator Safety
Inadequate Snow Conditions
WARNING
Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury .
Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.
If the machine becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the machine so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.
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.
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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.
S A snowmobile depends on the rider’s body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.
S Before allowing someone else use your snowmobile, know the ex-
tent 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.
S Don’t “jump” your snowmobile. Jumping may injure your back be-
cause 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.
S Be courteous to oncoming traffic by dimming your headlights and
reducing your speed. Your snowmobile is equipped with a high out­put headlamp system that may cause discomfort to operators of on­coming vehicles when on high beam.
S When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Allow ample stopping distances, and keep track of those following you. Drive defensively to avoid accidents.
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
in
MPH
40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
5 36 31 25 19 13 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
Frostbitein>> 30 min. 10 min. 5min.
WIND CHILL CHART (°C)
Wind
Speed
in
KPH
5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
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
Frostbitein>> 30 min. 10 min. 5min.
Actual Thermometer Reading (°F)
Equivalent Temperature (°F)
Actual Thermometer Reading (°C)
Equivalent Temperature (°C)
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals 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 AVERTISSEMENT
Pressure Cap Warning
This warning decal is found on the coolant bottle cover of liquid cooled models:
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SAFETY
Safety Decals and Locations
Track Warning
The track warning decal is located on the rear of the tunnel:
+
Passenger Warning
This snowmobile is designed for one operator only. A “No P assenger” warning decal is located on the lower console:
+
21
SAFETY
Safety Decals and Locations
Operation Warning
22
+
Safety Decals and Locations
Operation Warning
SAFETY
23
FEATURES AND CONTROLS
2
3
1
6
8
12
11
1. Brake Lever
2. Tachometer
3. Temperature Light
4. Engine Stop Switch
5. Throttle Control
9
6. Choke Control
7. Recoil Starter Handle
8. Fuel Filler Cap
9. Park Brake Lock
10. Headlight Dimmer Switch
11. Handlebar Grip Warmer/ Thumbwarmer Switch
12. Tether Switch
13. Master Cylinder
14. Dragont Ignition System Switch
4
5
7
13
10
14
24
FEATURES AND CONTROLS
1
11
10
9
8
7
6
2
3
4
5
1. Handlebar
2. Windshield
3. Headlight
4. Hood
5. Nosepan
6. Skis
7. Track
8. Suspension
9. Snow Flap
10. Taillights 1 1. Seat
25
FEATURES AND CONTROLS
Polaris DRAGON Ignition System
Your snowmobile is equipped with an ignition system feature t hat improves competition performance by increasing exhaust system temperature. The DRAGON Ignition System provides maximum “holeshot” performance for racing applications.
WARNING
DRAGON mode increases the exhaust system temperature and causes engine misfire and backfire. Flammable materials and vapors may ignite and result in fire and explosion, which may cause serious injury, death or property damage. Read the Owner’s Manual. Always follow all instructions and warnings.
DRAGON Mode Facts
S The DRAGON Ignition System is intended for competition use on
closed courses by experienced riders only.
S There is no benefit to using DRAGON mode for normal trail riding. S Unnecessary, extended or excessive use of DRAGON mode can re-
sult in severe engine damage, which is excluded from Polaris war­ranty coverage.
S DRAGON mode usually heats up the exhaust system within 5 to 20
seconds, depending upon the initial temperature of the exhaust sys­tem.
S Two different sounds may be heard when using DRAGON mode.
One sound is an erratic misfire that may be heard when the exhaust system is heating up. The other sound is a consistent misfire (with a slight rise in engine RPM) when the exhaust system is at target oper­ating temperature.
S DRAGON mode maintains the engine speed between 4500 and 5100
RPM.
S Be sure that the clutch engages at 5300 RPM or above to prevent
forward creep of the vehicle. See your dealer if the clutch needs ad­justment.
S Please refer to the Polaris jetting chart and use the recommended jet
for current temperatures as this system is sensitive to jet changes.
26
FEATURES AND CONTROLS
Polaris DRAGON Ignition System
DRAGON Mode Operation
1. Warm up the engine and track. See page 52.
2. When staged at the starting line, depress and hold the DRAGON (horn) button on the left handlebar (1).
3. Slowly advance the throttle to the wide-open position while keeping the button depressed.
4. Release the button when the start flag drops.
NOTE: The vehicle will launch
forward at wide-open throttle.
1
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