Polaris 550 IQ Shift, 550 IQ LXT, 550 IQ 136 User Manual

Download

550 IQ Shift

550 IQ 136

550 IQ LXT

Snowmobile Owner's Manual

for Maintenance and Safety

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.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923893 Rev 01 Printed in USA

*9923893 *

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide 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®

• Low emission vehicles (LEVs) 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.

The following are registered trademarks of POLARIS Industries Inc.:

POLARIS® IQ® PERC® THE WAY OUT® IQ SHIFT®

Copyright 2012 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.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A. Owner's Manual P/N 9923893 2013 550 IQ SHIFT / 550 IQ 136 / 550 IQ LXT

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 . . . . . . . . . . . . . . . . . . . . 40

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 98

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 102

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 119

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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.

Tunnel VIN

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of the tunnel): _________________________________________

Engine Serial Number (on recoil housing): ____________________________________

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.

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.

SAFETY

Operator Safety

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

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

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

CAUTION

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

NOTICE

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

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program beginning on page 62 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

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.

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. 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 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 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.

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.

SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 20.

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

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.

051039

0006.31

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.

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 • Tool Kit

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.

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to steer. If equipped, do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the cargo carrier.

SAFETY

Operator Safety

Rider Capacity

Driving 1-Up - Some POLARIS snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. Never carry a passenger on a single-rider snowmobile.

Driving 2-Up - Some POLARIS snowmobiles are designed for up to two riders. A decal on the console of these models indicates that the vehicle is designed for one operator and one passenger only.

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

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

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

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. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second. If you look back for only two seconds, your snowmobile will travel about 120 feet (36 m). If your speed is 60 MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in two seconds.

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

SAFETY

Operator Safety

Driver Awareness

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

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

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

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

SAFETY

Operator Safety

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.

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 hardpacked 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.

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.

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.

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 snowmobile into motion, but always operate within safety limits and, on 2-up machines, with respect for a passenger.

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 snowmobiles designed to carry a load or a passenger.

Maintenance

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.

NOTICE: When operating on icy surfaces or hard-packed snow, avoid overheat-

ing the slide rail and track. Lack of lubrication and cooling will cause overheating of the slide rail and track, resulting in premature wear and failure. If frequently operating in low cooling conditions, see your dealer for an optional wheel kit that will reduce the wear from overheating.

SAFETY

Operator Safety

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 over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

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

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

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

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

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

MPH

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

5 3631251913 7 1 -5-11-16

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

15 32 25 19 13 6 0 -7 -13

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

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

30 28 22 15 8 1 -5 -12

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

45 26 19 12 5 -2 -9 -16

50 26 19 12 4 -3 -10 -17

55 25 18 11 4 -3 -11

60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

WIND CHILL CHART (°C)

Wind

Speed

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

Km/h

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

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

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

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

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

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

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

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

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

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

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

Frostbite in >>

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

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.

SAFETY

Safety Decals and Locations

Track Warning

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

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

Snowmobiles designed for singlerider use have a warning decal on the lower right console.

WARNING

This vehicle is designed for operator only.

“NO PASSENGER”

Passenger Warning

Snowmobiles designed for an operator and one passenger have a warning decal on the lower right console.

WARNING

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

SAFETY

Safety Decals and Locations

Reverse Warning

The reverse warning decal is located on the upper console:

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.

Operation Warning

The operation warning decal is located on the lower console. See page 24 for the text.

SAFETY

Safety Decals and Locations

Operation Warning

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

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

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

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

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

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

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

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

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

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

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

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

• Before starting 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.

FEATURES

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Taillights

7. Rear Bumper

8. Snow Flap

9. Console Storage Compartment (if equipped)

10. Suspension

11. Tr a c k

12. Skis

13. Nosepan

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

15. Passenger Grab Handle (LXT)

16. Passenger Seat (LXT)

17. Passenger Backrest (LXT Accessory)

18. Cargo Bag (LXT Accessory)

19. Cargo Rack (LXT Accessory)

FEATURES

10 11

1. Fuel Filler Cap/Dipstick

2. Recoil Starter Handle

3. Reverse Indicator

4. Headlight Adjuster

5. Speedometer

6. Engine Stop Switch

7. Choke Lever

8. Ignition Switch

9. Brake Lever

10. Parking Brake

11. Handlebar Grip Warmer Switch

12. Thumbwarmer Switch

13. Electronic Reverse Button

14. Headlight Dimmer Switch

15. Throttle Control

Cargo Bag

Adjustment Positions

The accessory cargo bag is secured to the rear of the tunnel with straps.

The maximum weight capacity for the cargo area is 30 lbs. (14 kg). Always secure cargo before operating. Do not exceed the weight limit. Do not allow a passenger to sit on the cargo area.

Adjustable Headlights

Adjust the headlight beam by moving the adjuster to the left or right.

Passenger Grab Handle

If equipped, the passenger grab handles can be adjusted for rider preference.

1. Remove the hardware securing the grab handles to the grab handle tube.

2. Reposition the grab handles to one of the three available positions and reinstall the hardware securely.

FEATURES

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. A-arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

THE PERFECT FIT

Low

Preload

High

Preload

Front Suspension Adjustments

Shock Spring Preload

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

To change front shock spring preload, grasp the spring and rotate it.

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 the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.

Tip: Not all models have shocks with thread adjustable spring preload. See your

dealer for more information.

NOTICE: On some models equipped with a plastic adjuster nut, the nut will

break if it is unscrewed from the threaded body. Do not force the nut if resistance suddenly increases while you’re turning it.

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.

Refer to the suspension setup label on your snowmobile, or 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.

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.

Tip: Keep the suspension pivot points lubricated. This will reduce moisture and

rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. Refer to the Pre-Ride Suspension Inspection on page 45.

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 86.

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the 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.

Tip: 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). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload.

Suspension Recommended Sag Adjustment

IQ (121) 4-5 inches (10-13 cm) Torsion Spring

Preload

IQ Comfort

(136)

Tip: This is only an initial setup, and final spring preload may vary based on rider

preference and riding conditions. Accessory springs with a higher load rating are available for some models. Please see your dealer for availability.

4-5 inches (10-13 cm) Torsion Spring

Preload

See

Page

THE PERFECT FIT

IQ Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort.

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

Soft Medium Firm

Limiter Strap Position (Ski Pressure)

Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. Tighten the straps to increase ski pressure. Loosen the straps to reduce ski pressure.

1. Remove the nuts and flat washers from the upper limiter straps.

2. Relocate the straps to the desired position.

3. Reinstall the nuts and washers. Tighten securely.

Upper

Nuts

THE PERFECT FIT

IQ 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.

THE PERFECT FIT

IQ Rear Suspension Adjustments

Suspension Coupling

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

• Increased load carrying capacity (2-up)

THE PERFECT FIT

HIGH

LOWLOW

MEDIUM

FRSS

RRSS

IQ 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.

To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.

Tip: Your dealer can help you with initial

setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also available from your dealer.

THE PERFECT FIT

Traction Products

Carbide 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 93.

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

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

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used.

Install the appropriate wear strip kit. See your dealer.

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

NOTICE: Whenever wear strips are relocated, be sure there's adequate stud

clearance to the tunnel. Lack of clearance may result in damage to tunnel.

THE PERFECT FIT

Handlebar Adjustments

When making handlebar adjustments, always be sure the handlebars, brake lever and throttle lever operate smoothly and do not contact the fuel tank, windshield or any other part of the vehicle when the handlebars are turned fully to the left or right.

Upper Bolts

Lower Bolts

Handlebar Position

Follow these steps to adjust handlebar position.

1. Remove the handlebar cover.

2. Loosen the four upper and four lower adjuster block bolts.

3. Adjust the handlebar to the desired position.

4. Torque the front bolts first, then torque the rear bolts. Torque the bolts to 15-17 ft. lbs. (20-23 Nm).

5. Reinstall the handlebar cover.

THE PERFECT FIT

Handlebar Adjustments

Handlebar Angle

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

1. Remove the handlebar cover.

2. Loosen the four upper adjuster block bolts.

3. Adjust the handlebar to the desired angle.

4. Torque the bolts to 15-17 ft. lbs. (20-23 Nm).

5. Reinstall the handlebar cover.

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.

Tip: Exhaust systems are critical safety areas that must use approved POLARIS

parts. Please see your POLARIS dealer for service.

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.

Item See Page

Drive Belt Condition 83, 85

Steering System 44

Recoil Rope 45

Cooling System Seal 73

Parking Brake Lock/Brake Lever/Brake System 42, 43, 77

Auxiliary Shut-Off Switch (Engine Stop Switch) 46

Ignition Switch 46

Taillight/Brakelight/Headlight 46

Suspension Mounting Bolts 45

Skags (Wear Bars) 37, 93

Ski Spindle Bolts 45

Hood Straps/Latches 45

Throttle Lever/Safety Switch 56, 57

Rear Wheel Idler Bolts 89

Tether Switch/Strap (accessory) 46

Track Alignment/Condition 44, 90

Rail Slide Condition 94

Chaincase Oil Level 68

Injection Oil Level 53

PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING! Worn, damaged, or malfunctioning components may cause serious

injury or death. Before starting the engine, check all components to be sure of proper operation.

Read and Understand Your Owner's Manual

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

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.

Throttle Safety Switch

Test the throttle safety switch system before the machine is operated. See page 56.

PRE-RIDE INSPECTIONS

1/2” (1.3 cm)

Before Starting the Engine

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 1/2” (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 79 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 78.

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.

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

3. Master Cylinder Reservoir/ Cover

4. Fluid Level Indicator

Lock Engagement

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

Tip: If the brake lever is squeezed tightly enough, the lock will move freely into

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

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

Lock Release

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

Track

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.

Tip: Track damage or failure caused by operation on ice or poor lubrication con-

ditions voids the track warranty.

PRE-RIDE INSPECTIONS

Before Starting the Engine

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.

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.

Pre-Ride Suspension Inspection

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

Item Check Page

Suspension mounting bolts Tightness --

Rear idler wheel bolts Tightness 89

Rear idler adjusting bolt locknuts Tightness --

Torque arm bolts Tightness --

Carrier and bogie wheel bolts Tightness --

Front torque arm limiter strap Condition --

Rail slide Condition 94

Track Tension 88

All rear suspension components Lubrication 66

Ski runner/skag Condition 93

Ski spindle bolts Tightness --

Tie rod end nuts Tightness --

PRE-RIDE INSPECTIONS

Start the Engine and Check

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 41.

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.

Ignition Switch

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

Tether Switch (if equipped)

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

Lighting

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

Mirrors (if equipped)

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

Operating Area

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

OPERATION

Starting the Engine

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

1. Turn the fuel valve on. See

2. Turn the key to the ON

3. Pull the engine stop switch

4. If starting a cold engine,

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

NOTICE: Don't pull the starter rope to the fully extended position and don't allow

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

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

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

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

page 52.

position.

CHOKE POSITIONS

OFF

up to the RUN position.

1/2 CHOKE

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

FULL CHOKE

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

it to snap back into the housing. Damage may result.

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

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

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

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 56 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

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 (accessory) Interrupts ignition circuit All

THROTTLE

CONDITION

Break-In Period

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.

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

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

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

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

OPERATION

Break-In Period

Oil Injection System

Always check and fill the oil tank when refueling. See page 53.

NOTICE: Serious engine damage can occur without the proper lubrication.

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection systems. POLARIS recommends the use of POLARIS Premium 2Cycle Semi-Synthetic Oil or VES Gold Plus 2-Cycle Oil for this engine. See page 102 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.

Drive Belt Break-In

The break-in period for a new drive belt is 30 miles (48 km). During this time, vary the throttle position under 50% and limit full throttle use.

New drive belts should be washed with warm, soapy water and allowed to air dry prior to use.

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

Always take time to warm up the belt and driveline prior to operating the snowmobile. Free the track and skis from the ground before engaging throttle.

OPERATION

Track Warm-Up

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.

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 4” (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.

Tip: 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.

Slide Rail and Track Cooling

Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure.

1. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.

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

OPERATION

WARNING

Fuel

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.

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.

OPERATION

OFF

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. Do not use fuel containing more than 10% ethanol (including E85).

NOTICE: Using fuels with a lower than recommended octane or operating with

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 102 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.

Fuel Valve

The fuel valve is located between the oil bottle and engine intake duct. Turn the fuel valve off whenever the snowmobile is stored or parked.

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.

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

OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light may flicker at times due to oil movement in the bottle, but when the light comes on and remains on, add the recommended oil before further operation. See page 49 for oil recommendations.

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

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.

NOTICE: Operating the snowmobile without adequate engine lubrication can

Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 49 for oil recommendations.

The POLARIS oil cap on the oil bottle is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

result in serious engine damage. Always check the oil level when refueling. Add oil as needed.

OPERATION

Carburetion

NOTICE: Making non-recommended adjustments could result in vehicle or

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.

engine damage as well as denial of warranty claims. We recommend that all carburetor adjustments be performed by your POLARIS dealer.

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 of -15° to +5° F. (-26° to -15° 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 74 for more information.

NOTICE: A main jet that's too small will cause a lean operating condition and

Tip: It's the owner's responsibility to ensure that the correct jets are installed in

may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in the specifications section of this manual. See page 98.

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.

OPERATION

Engine Stop Switch

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

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.

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.

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.

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic machine

behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine.

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor 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.

OPERATION

Electronic Reverse (PERC)

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 on page 59. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse

Tip: The engine will activate a misfire mode and begin to stutter after 45 sec-

onds in reverse. This feature protects the engine from overheating and will reset when it is shifted into forward or when the engine is stopped and restarted.

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.

OPERATION

Electronic Reverse (PERC)

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 sec-

ond, 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.

Tip: The maximum engine RPM will be 6000 when in reverse. Tip: If the engine stops running, the snowmobile will be in forward gear when it's

restarted.

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 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.

OPERATION

Towing

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

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

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.

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.

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

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

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

Please read the U.S.A EPA Emissions Limited Warranty beginning on page 117, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.

Non-ionizing Radiation

This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

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 119.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals.

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

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

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

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

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

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.

Item See

Clutch Alignment Offset (without belt)

Drive Belt Condition 83 II II

Clutches (disassemble) 82 CC C

Belt Tension -- II II

Clutch Sheaves 82 II II

Engine Mounts -- IIII

Engine Mounting Plate -- III

Engine Torque Stop 85 II II

Cylinder Head Bolts -- III

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- III

Recoil Rope -- II II

Spark Plug Condition 71 II IRI

Exhaust Pipe 73 II

Exhaust Retaining Springs

Page

150 mi.

(240 km)

82 II I

73 II II

(800 km)

CLUTCH

ENGINE

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II

Hose Condition -- IIII

Fluid Leaks -- IIII

Brake Pads 77 IIII

Brake Disc -- IIII

Parking Brake 43 II II

Brake System 42, 77 I

Brake Fluid 78 I

Pilot Air Screws -- III

Carburetor (synchronize)

Idle RPM -- II I

Throttle Lever 57 II I I I

Oil Pump Lever (synchronize)

Throttle Cable 67 LL L

Choke Cable 67 LL L

Choke 67 II I

Vent Lines -- II II

Fuel Lines 73 II I I I

Fuel Filter 73 RR

Oil Filter 72 RR

Oil Lines 72 III

Air Box -- III II

Drain and Water Traps 75 III

Auxiliary Shut-Off Switch

Throttle Safety Switch 56 II I I I

Ignition Switch -- II I I I

Taillight 46 II I I I

Brakelight 46 II I I I

Headlight 46 II I I I

Page

150 mi.

(240 km)

FUEL MANAGEMENT

74 III

-- II I

ELECTRICAL

56 II I I I

(800 km)

BRAKES

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- II I

Suspension Mounting Bolts

Steering Fasteners -- II I IC

Rear Suspension Fasteners

Suspension Shock Oil -- II II

Cooling System 73 II II

Drive Shaft Bearing 67 LL L I

Jackshaft Bearings 96 LLL I

Skags (Wear Bars) 93 II I I I

Ski Saddle/Spindle Bolts

Steering Arm(s) -- I

Drive Chain Tension 76 II I I I

Hood Latches 45 II I II

Rear Wheel Idler Bolts 89 II I II

Idler Bolt Jam Nut 89 II I I I

Rear Suspension Pivot Shafts

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 46 II I I I

Track Alignment 90 II I I I

Track Tension 88 II I II

Front Limiter Strap -- II I I I

Rail Slide Condition 94 I

Chaincase Oil 68 II IRI

Page

150 mi.

(240 km)

-- II I I I

66 LL L

500 mi.

(800 km)

CHASSIS

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

Lubrication

Front Suspension

The front suspension does not require lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 62 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer.

IQ Rear Suspension (121)

IQ Comfort Rear Suspension (136)

Lubrication

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.

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.

MAINTENANCE

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.

MAINTENANCE

Lubrication

Chaincase Oil

Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 62. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 102 for the part numbers of POLARIS products.

Oil Check

1. Position the vehicle on a level sur-

face.

2. View the oil level at the sight glass.

3. Remove the fill plug (3) and add the

recommended oil as needed. Do not overfill.

4. Reinstall the fill plug, making sure it

is seated properly.

MAINTENANCE

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the drain plug (4) and drain

the oil into a drain pan. Allow the oil to drain completely.

3. Clean off all metal shavings from the

plug.

4. Install a new sealing washer on the

drain plug.

Tip: The sealing surfaces on the drain plug and the oil tank should be clean and

free of burrs, nicks or scratches.

5. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

6. Remove the fill plug. Clean off all metal shavings from the plug.

7. Add 9 oz. (265 ml) of the recommended oil. Do not overfill.

8. Reinstall the fill plug, making sure it is seated properly.

MAINTENANCE

Spark Plugs

It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. Change the spark plugs every 2000-2500 miles (32004000 km).

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

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

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

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

• Always carry spare spark plugs.

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

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

Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too

age if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See the specifications section beginning on page 98.

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.

MAINTENANCE

Spark Plugs

Spark Plug Condition

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.

The tip should not be white. A white insulator tip indicates overheating, 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. Rotate the spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Reinstall the spark plug cap.

MAINTENANCE

Intake Filters

The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow.

NOTICE: Operating the snowmobile

Oil Lines

Inspect oil line condition every 1000 miles (1600 km).

Oil Filter

The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

Tip: The direction of the arrows indicates

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.

the direction of flow through the filter.

Fuel Pump

All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.

MAINTENANCE

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the under-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.

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

Cooling System

Inspect the fan intake and outlet edge seal at the input and output for cracks, loosening of duct and blockage or obstructions. Make any necessary repairs promptly.

Exhaust System

Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting.

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

1. Open the hood and inspect the muffler and pipes for cracks or dam-

2. Check for weak or missing retaining springs or damper/support

3. Check for loose clamps on the pipe covers.

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

age.

grommets.

MAINTENANCE

Carburetor

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

NOTICE: Operating the snowmobile with incorrect jetting can result in serious

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

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

MAINTENANCE

Carburetor Water/Sediment Trap

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

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 fuel warnings on page 51.

Cleaning Procedure

1. Turn the fuel valve off.

2. Place a container or shop

towels below the plug to catch drained fuel.

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 clamp.

5. Repeat the draining procedure for any remaining traps.

MAINTENANCE

Drive Chain Tension

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

1. Rotate the driven clutch counter-

clockwise 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.

MAINTENANCE

Brakes

Hydraulic Brake Inspection

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

42. Brake pads must be replaced when the brake pad material becomes thin-

ner than the backing plate (approximately 1/16” or 1.5 mm). A kit is available for replacing brake pads. See your dealer.

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” or 1.5 mm

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material

(Replace when thickness is less than 1/16” or 1.5 mm).

Excessive Lever Travel

Hydraulic brakes are selfadjusting, but if excessive brake pad clearance develops, bring the machine to an authorized POLARIS dealer for inspection and adjustment.

MAINTENANCE

Brakes

Brake Fluid

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.

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.

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.

Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 102 for the part numbers of POLARIS products.

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

up spills immediately.

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.

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.

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

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

flow of fluid into an approved container.

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

valve 3/4 of a turn to release air.

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

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

solid stream free of air bubbles.

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.

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

See page 78.

8. Reinstall the gasket and cover.

MAINTENANCE

Lights

Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel.

Headlight Bulb Removal

1. Remove the plenum covering

from the headlight assembly.

2. Lift the rubber boot to expose

the bulb.

3. Push down on the spring (1) to

release it from the housing.

4. With the wire harness (2)

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

5. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

Headlight Bulb Installation

1. Hold the bulb by its metal base and install it into the wire harness.

Tip: Recommended replacement bulbs include H4, HB2 and 9003 bulbs.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Verify headlight aim.

MAINTENANCE

Lights

Taillight/Brakelight Replacement

1. Remove the screws securing the taillight lens. Remove the lens.

2. Push the bulb inward and turn it counter-clockwise to remove it.

3. Install a new bulb. Push the bulb inward and turn it clockwise to

secure it.

4. Reinstall the taillight lens.

MAINTENANCE

Clutch System

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

NOTICE: If you become aware of higher than normal clutch engagement or an

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment.

unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.

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

The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

MAINTENANCE

Clutch System

Drive Belt Condition

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

107. For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the snowmobile.

Drive Belt Removal

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete

3. Lock the parking brake.

4. Open the hood.

5. Remove the left side panel.

6. Locate the L-wrench in the tool kit. Install the wrench into the open

7. Turn the wrench clockwise until the sheaves open far enough to

snowmobile must be stopped after forward motion to prevent damage to components during belt removal.

stop.

threaded hole in the outer sheave of the clutch.

remove the belt.

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after the break-in period by readjusting belt deflection.

Tip: To ensure satisfactory belt life, install belts so they operate in the same

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

2. Rotate the L-wrench counter-clockwise to tighten the sheaves while

working the belt to the outer edge of the sheaves.

3. Remove the L-wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

6. Break in the new belt. See page 49.

Drive Belt

Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. POLARIS recommends the use of O.E.M. belts. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance.

Tip: A worn belt will continue to function, but will not deliver maximum perfor-

mance. Always carry a spare belt in case of an emergency.

MAINTENANCE

.010-.030 inch (.25-.75 mm)

Clutch System

Drive Belt Deflection

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

Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inch (3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave

of the clutch (see page 83). Turn the wrench clockwise slightly to remove pressure from the sheaves.

2. Loosen the 7/16-inch jam nut.

3. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward (counter-clockwise) to decrease the distance.

4. Tighten the jam nut. Store the L-wrench in the tool kit.

Torque Stop

Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010.030 inch (.25-.75 mm) from the engine case.

Adjust if necessary, and lock the jam nut.

MAINTENANCE

Track Maintenance

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the

machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift and

support the rear of the snowmobile off the ground.

2. Rotate the track by hand to

check for damage.

3. Carefully examine the track

along the entire length of

each rod ( to check for breakage.

4. Replace the track if any rod

damage is found.

). Bend the track

MAINTENANCE

Track Maintenance

Track Lubrication

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication.

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

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

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

Tip: Track damage or failure caused by operation on ice or under other poor

lubrication conditions will void the track warranty.

MAINTENANCE

Track Maintenance

WARNING! Moving parts can cut and crush body parts. When performing the

checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running.

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment.

TRACK TENSION DATA CHART

Suspension Weight

IQ (121) 10 lbs. (4.54 kg) 16 in. (40 cm)

IQ Comfort (136) 10 lbs. (4.54 kg) 16" (40 cm)

Tip: Tension adjustments should be made only after the track is warmed up and

limber.

Measurement

Location

ahead of rear

idler shaft

ahead of rear

idler shaft

Slack

Measurement

7/8-1 1/8 in.

(2.2-2.9 cm)

7/8-1 1/8 in.

(2.2-2.9 cm)

1. Turn the engine off.

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

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

at the specified distance (see chart) ahead of the center of the rear idler wheel. Measure at the point where the weight is hanging.

MAINTENANCE

Slack Measurement

Lock Nut

Adjusting Screw

Track

10 lbs. (4.54 kg)

Shaft

Bolt

16 in. (40 cm)

Track Maintenance

Track Tension

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

and the plastic slider. Refer to the Track Tension Data Chart on page

88.

If the track needs adjustment:

5. Loosen the rear idler shaft bolt.

6. Loosen the locknuts.

7. Tighten or loosen the track adjusting screws to provide equal adjust-

ment on both sides of the track.

8. Repeat the measurement on the other side of the track.

Tip: Check more frequently when the machine is new.

9. Start the machine and slowly rotate the track at least five revolu-

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

10. Check track alignment (see page 90) and adjust as necessary.

11. Tighten the locknuts.

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

MAINTENANCE

Track Maintenance

Track Alignment

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

1. Safely support the rear of the machine with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track

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

3. Inspect track alignment by

looking through the track window to make sure the rails (X) are evenly spaced on each side. If the track runs to the left, loosen the idler shaft bolts, then loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the idler shaft bolts, then loosen the right locknut and tighten the right adjusting bolt.

4. After adjustments are com-

plete, tighten the locknuts and torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

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

MAINTENANCE

Steering System

Steering Inspection and Adjustment

Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

MAINTENANCE

Steering System

Ski Alignment

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer.

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10

inches (25.4 cm) forward from the center of the ski mounting bolt. See illustration. At this point, measure between the skis. This is measurement X.

3. Perform the same measurement rearward from the center of the ski

mounting bolt. This is measurement Y.

4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than

the Y measurement. If the skis are misaligned, see your dealer for alignment correction as camber adjustment may also be affected.

10 in.

(25.4 cm)

10 in.

(25.4 cm)

MAINTENANCE

Steering System

Ski Skags

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

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

Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original diameter.

Tip: Carbide skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

1. Raise and support the front of

the machine so the skis are approximately 6 inches (15.2 cm) from the ground.

2. Remove the attaching nuts

and pry the skag downward.

3. Remove the rear end of the

skag.

4. Remove the front end of the

skag.

5. Reverse the steps to install a

skag.

MAINTENANCE

Replace when worn to top of groove

Minimum

Thickness

Steering System

Rail Slide Wear

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

MAINTENANCE

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 4 inches (10 cm) off the ground.

Remove the key and cover the machine.

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your machine in peak operating condition

Extended Storage

Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 102 for the part numbers of POLARIS products.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint).

The machine should be stored in a dry garage or shed, out of direct sunlight, and covered with a fabric snowmobile cover. Plastic tarp may cause condensation to form and damage snowmobile components.

Controls and Linkage

Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 63.

MAINTENANCE

Extended Storage

Bearings

Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All-Season Grease or a similar high quality grease to prevent corrosion.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer.

Engine and Carburetor Protection

Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil. Follow the engine fogging instructions provided on the container.

Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. Follow the instructions on the container, running the engine for five minutes to get additives through the entire fuel system. Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.

If stabilizer is not used, drain the carburetors by removing the water trap drain plugs. See page 75.

Tip: Jet restriction caused by improper storage can cause lean conditions and

very poor slow speed driving quality.

Polaris 550 IQ Shift, 550 IQ LXT, 550 IQ 136 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual