Polaris 600 IQ Widetrak, 600 Widetrak IQ User Manual

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Pantone 425C

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. 9922596 Rev 01 Printed in USA

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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.

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The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

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WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

• Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational 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 technician.

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

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

utility vehicles

(MSD)

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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 in acc uracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2010 600 Widetrak Owner’s Manual P/N 9922596

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 56

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 117

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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INTRODUCTION

Important Notes for Owners and Drivers

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

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

Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

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

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

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INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education campaign. We encourage state and provincial gove rnments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.

In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.

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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 wi th one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number: ___________________________________________________

Tunnel VIN ( (lower right side of the tunnel)

Engine Serial Number (on valve cover): _______________________________________

Key Number: ___________________________________________________________

): _________________________________________________________

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SAFETY

Operator Safety

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

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

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SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program outlined begi nning on page 77 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.

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SAFETY

Operator Safety

Stay Clear of Track

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

WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. 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.

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SAFETY

Operator Safety

Riding Position

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

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.

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.

Always carry the owner’s manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

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SAFETY

051039

0006.31

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

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 23.

WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.

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SAFETY

Operator Safety

Rider Capacity

Your snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only.

WARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or death. 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” the snowmobile.

Snowmobiles designed for two riders should never be operated with more than two people on board. 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.

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SAFETY

Operator Safety

Cargo Capacity

See page 32 for cargo loading information.

WARNING! Overloading the cargo carrier can cause loss of control resulting in severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg). Never exceed the cargo carrier capacity.

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills.

WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle.

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SAFETY

Operator Safety

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 snowmobile to a stop in the distance illuminated by the headlight.

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SAFETY

Operator Safety

Driver Awareness

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

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your snowmobile 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.

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SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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

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

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

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SAFETY

Operator Safety

Ice and Snow Build-up

WARNING! Ice and snow build-u p may interfere with the steering of your

snowmobile, 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 Downhill

When riding downhill, shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

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SAFETY

Operator Safety

Driving 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.

Driving in Hilly Terrain

WARNING! Climbing a hill or crossing th e face of a slope may result in loss of

balance and snowmobile rollover, 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 snowmobile to maintain proper balance and avoid possible rollover.

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 snowmobile 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 snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the parking brake, and descend the hill carefully.

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SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine.

Any servicing that requires operation without a belt must be performed by your dealer.

Intake Silencer

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

NOTICE: Damage to the engine may occur if the intake silencer or filter are

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 fr om ice and snow before attempting to drive. Warm the drive belt by allowing the engine to idle in neutral for several minutes. 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.

removed.

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.

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SAFETY

Operator Safety

Inadequate Snow Conditions

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

NOTICE: Driving in too little snow will result in excessive wear and damage to WARNING! Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the snowmobile so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.

the slide rail, track and/or engine.

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SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.

• A snowmobile depends on the rider’s body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they’ve taken a snowmobile safety course and have an operator’s certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

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

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

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

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

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SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Wind

Speed

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 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

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

-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

KPH

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

Frostbite in >>

Actual Thermometer Reading (_C)

Equivalent Temperature (_C)

-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

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

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

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

30 min. 10 min. 5 min.

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

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SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals 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 Warning

This warning decal is found under the hood on the air plenum:

WARNING Do not operate 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.

Pressure Cap Warning

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

WARNING Do not open hot. Test or replace when changing coolant. Press

down and turn to release cap. 13 PSI

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SAFETY

Track

Warning

Safety Decals and Locations

Passenger Warning

Snowmobiles designed for an operator and one passenger have a warning decal on the console. For more information on operating with a passenger, see page 13.

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

Track Warning

WARNING Stay clear of track. Do

not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

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SAFETY

Reverse Warning

Operation

Warning

Safety Decals and Locations

Reverse Warning

Polaris snowmobiles equipped with standard reverse and will have this decal on the 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.

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SAFETY

Safety Decals and Locations

Operation Warning

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

WARNING

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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FEATURES

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield

7. Mountain Bar

8. Handlebar

9. Fuel Filler Cap

10. Seat

11. Backrest

12. Taillights

13. Cargo Carrier

14. Rear Bumper

15. Snow Flap

16. Track

17. Suspension

18. Grab Handle Heater Switch

19. Backrest Adjustment Knob

20. Passenger Grab Handle

21. Seat Latch

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FEATURES

11 10

1. Glove Box

2. MFD Display

3. Ignition Switch

4. 12-Volt DC Outlet

5. Shifter

6. Work Light Switch

7. Brake Lever

8. Handlebar Grip Warmer Switch

9. Thumbwarmer Switch

10. Throttle Control

11. Engine Stop Switch

12. Electronic Reverse Button

13. MFD Control Switch

14. Headlight Dimmer Switch

15. Parking Brake Lock

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FEATURES

Operator/Passenger

Raise/Lower

Seat Latch

Storage Area

Backrest

The backrest is adjustable for either operator or passenger use.

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

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

3. Always tighten the knobs securely after adjusting.

Seat Latch

Release the seat latch and raise the seat to access the battery and under-seat storage area.

Check the seat latch before each use of the snowmobile. Push downward on the seat near the seat latch, then attempt to raise the seat by pulling upward on the right-hand passenger grab handle. Make sure the latch is secure before riding.

Under-Seat Storage

When using the under-seat storage area to transport supplies and other items, pack the items securely to prevent them from moving around in the storage area. Smaller items should be placed in bags or containers to keep them secure.

Page 35

Adjustable Headlights

Glove Box Latch

Move the headlight adjuster to raise or lower the headlight beam.

• Move the adjuster to the left to lower the beam.

• Move the adjuster to the right to raise the beam.

Glove Box

The glove box is a heated dry storage area intended for drying wet gloves. Do not

use the glove box for items that could be damaged by heat.

Turn the knob to release the glove box cover latch and open the cover.

FEATURES

Page 36

FEATURES

Cargo Carrier

WARNING! Overloading or towing

improperly can alter vehicle handling and can cause loss of control.

• Do not exceed the cargo carrier capacity.

• Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger, or when towing.

• Always secure cargo before operating vehicle.

• Overloading or carrying tall, offcenter, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the carrier.

• Be careful if load extends over the side of the carrier.

The maximum weight capacity for the cargo carrier is 75 lbs. (34.1 kg). Do not allow a passenger to sit on the seat back or in the cargo carrier.

NOTICE: Do not drive aggressively or jump your vehicle when operating with

heavy loads in the cargo carrier. This may cause vehicle damage.

Page 37

Passenger Grab Handle

Adjustment

Bolt

12-Volt DC Outlet

The position of the passenger grab handles can be adjusted for rider preference.

1. Remove the adjustment bolt.

2. Reposition the grab handles to

one of the two adjustment positions on the grab handle tube between the operator seat and the passenger seat.

3. Reinstall the adjustment bolt

and tighten securely.

12-Volt DC Outlet

Use the 12-volt DC outlet to power a global positioning sensor (GPS), heated helmet shield, utility light, cell phone or other accessories.

The 12-volt DC outlet is located on the console near the shift lever.

FEATURES

Page 38

FEATURES

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate, flicker or flash momentarily..

Check Engine Light Status Indicates

Solid or Flickering Detonation detected Flashing Severe detonation detected, RPM will

You may notice decreased engine RPM and performance when DET is activated, but in most cases DET activation is temporary, and the timing will return to normal automatically.

If severe detonation occurs, the check engine light will begin to flash. The engine will enter a limp home mode (and RPM will be limited to 6500 RPM) and stay in this mode until the engine is shut down and restarted.

The most likely causes of severe detonation are shown in the table below. Refer to the table for troubleshooting information.

DET Troubleshooting

Cause of DET Activation Solution

Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel

resistor installed Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter See your Polaris dealer for service Alcohol-based fuel additive used

with Ethanol fuel

Improper engine modifications Do not modify the engine

be limited

Verify correct fuel resistor for fuel type in tank

Do not add de-icers or additives that contain any form of alcohol while using up to 10% ethanol fuel

Page 39

Instrumentation

MFD Component Identification

Item

1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator

Digital Display Identification

Item

1 RPM or Speed

Altitude (if equipped) Service Interval

2 Electrical System Voltage

Level

3 MAX - Maximum MPH/

4 Air Temp (if equipped)

5 Miles/Kilometers 6Hours

7 Fuel Level

KPH or RPM MPH -Miles per hour KPH - Kilometers per hour RPM -Engine crankshaft

revolutions per

minute

Engine Temp Degrees Celsius Degrees Fahrenheit

Trip 1/Trip 2/Trip F Service Label Altitude Label

FEATURES

Page 40

FEATURES

MFD

Control

Switch

SET

MODE

Instrumentation

MFD Settings

The MFD control switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instructions are outlined on the following pages.

MFD settings can be made with the engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down, and turn the ignition key to the START position briefly to activate the gauge. The gauge will illuminate for about 90 seconds.

Standard vs. Metric

The MFD will display either standard or metric units of measurement. While viewing a screen that displays measurements (MPH, km/h or temperatures), press and hold the MODE switch until the unit of measurement changes (about 10 seconds).

Page 41

FEATURES

Instrumentation

MFD Settings

Speedometer/Tachometer

If your model is equipped with both analog and digital displays, the speedometer and tachometer can be viewed in either display. If the analog display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).

To change viewing preferences, press and hold the MODE button for three seconds. When the button is released, the new setting becomes active and screen colors change. See table below.

Option

1 Speed RPM Blue “MPH” Blue

2 RPM Speed Red

Analog

Display

Digital

Display

Analog Screen

“X100RPM”

Digital

Screen

Backlight

Red

Backlight

Page 42

FEATURES

Instrumentation

MFD Digital Display Programs

Press and release the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.

Performance Program

Press and release the MODE button until the performance program screen is active. The default display for this screen includes electrical system voltage (unless equipped with ACE suspension adjustment), fuel level (if equipped) and either speed or tachometer, whichever is selected. See page 37.

Press and release the SET button to cycle through the following screens: odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is low) and clock (if equipped). Use the following procedures to make changes to these screens.

Odometer Setting

The odometer records the vehicle's total distance traveled since manufacture. The odometer cannot be reset.

Trip Settings

Trip 1 and T rip 2 are odometers used to check fuel mileage or to keep track of distance traveled. Both odometers can be reset to zero.

1. Enter the Performance Program.

2. Press and release the SET button until the desired trip screen is active.

3. Press and hold the SET button for two seconds to reset the trip odometer to zero.

4. Press and release the SET button to cycle through additional screens.

Page 43

Instrumentation

MFD Digital Display Programs

Performance Program

Trip Settings

Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.

The Trip F odometer records distance traveled, and the fuel symbol continues to blink, until enough fuel is added to raise the level above 1/4 of a tank. The Trip F odometer will automatically reset to zero after refueling.

FEATURES

Page 44

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Clock Setting (if equipped)

1. Enter the Performance Program.

2. Press and release the SET button until the clock screen is active.

3. Press and hold the SET button for five seconds.

4. When the hour starts flashing, press the SET switch once to advance one hour. (Press and hold the SET button to advance the hours quickly.)

5. Press and release the MODE button to save the hour. The minutes will begin flashing.

6. Set the minutes in the same manner.

7. When finished, press and release the MODE button to save the new setting. If the MODE button is not pressed within ten seconds, the gauge will automatically save the new entry.

Page 45

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electrical system voltage level, fuel level (if equipped) and either engine coolant temperature, air temperature (accessory) or altimeter (accessory).

Press and release the SET button to cycle through the following screens: hour meter, engine temperature, air temperature (available as an accessory), altimeter (available as an accessory) and turbo boost (if equipped).

Hour Meter

The hour meter records the total hours of engine operation since manufacture. This meter cannot be reset.

Engine Temperature

A thermometer measures water temperature, giving an indication of engine temperature.

Air Temperature (if equipped)

The MFD displays actual air temperature in either standard or metric units.

1. Enter the Engine Program.

2. Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.

Page 46

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

Altitude (if equipped)

The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment.

1. Enter the Engine Program.

Tip: Press and hold the MODE switch for ten sec-

onds to switch between standard and metric units of measurement. When "ALt" displays, the program is in the metric mode.

2. Press and release the SET button until the altimeter screen is active.

3. Press and hold the SET button for five seconds. When the digits begin to flash, release the button.

4. Press and release the SET button once to advance 50 feet (15 m).

Tip: Press and hold the SET button to advance quickly by 100-foot (30 m) incre-

ments.

5. Adjust the altitude display to within 50 ft. (15 m) of current altitude.

Tip: The gauge reads barometric pressure and allows the rider to comp ensate

for daily fluctuations in air pressure. The gauge can adjust the displayed altitude to +/- 1300 ft. (396 m) from the preset value. It will adjust up to +1300 ft. (396 m) above the calibrated altitude. Once the +1300 ft. (396 m) offset has been reached, the next adjustment is -1300 ft. (396 m) from the calibrated altitude, and 50 ft. (15 m) will be added to the altitude each time the SET button is pressed.

6. Press and release the MODE button to set the reading at the adjusted value. If the MODE button is not pressed within ten seconds, the gauge will automatically save the new entry.

Page 47

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped).

Press and release the SET button to cycle through the Maximum Vehicle Speed, Maximum Engine RPM and Service Interval Reminder screens.

Maximum Speed/Maximum RPM

The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display.

1. Enter the History Program.

2. Press and release the SET button until one of the two screens is active.

Tip: The MPH and RPM values are both reset at

the same time. Reset the values before each run to obtain accurate readings.

3. Press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM.

Tip: Due to electrical noise, the MFD may occa-

sionally display MAX MPH/RPM values that are not representative of actual values.

Page 48

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG" will flash in the icon area for five seconds each time the engine is started (until the service reminder is reset.) Use the following procedures to reset the reminder.

To reset the reminder at the existing interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is active.

3. Press and hold the SET button for ten seconds, continuing to hold even after the display begins to flash.

4. When the display stops flashing, release the button. The service interval has been reset.

Page 49

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

To reset the reminder at a new interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is active.

3. Press and hold the SET button for five seconds, until the hours begin to flash. Immediately release the button.

4. Press the button again, up to five times, to advance the reminder in 50-hour increments.

Tip: The maximum interval is 250 hours.

5. Press and release the MODE button to save the new settings.

To disable the service interval reminder:

1. Press the SET button once after reaching 250 hours on the display. The gauge will display "OFF".

Page 50

FEATURES

Instrumentation

MFD Battery Replacement

Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer.

1. Remove the plenum from the underside of the hood.

2. Locate the black battery compartment. It has a red wire and a brown wire with a white stripe. It's located about three inches down the main harness from the point where the harness connects to the MFD.

3. Cut the plastic cable tie from the outside of the compartment.

4. Carefully cut the bottom of the compartment (opposite the wires) to separate the heat-sealed seams. Squeeze the corners of the compartment inward so the battery is visible.

Tip: Note the orientation of the battery before removing it. An incorrectly

installed battery will not maintain the clock.

Page 51

FEATURES

Instrumentation

MFD Battery Replacement

5. Using needle-nose pliers, grasp the battery and rotate it so the leading edge of the battery is raised away from the battery holder. Pull the battery out gently .

Tip: The battery will not come out of the holder unless the leading edge of the

battery is raised. Hold the battery compartment, not the wires, while removing the battery. Pulling on the wires will separate them from the battery holder.

6. Install a new battery with fingers only.

7. Seal the end of the battery compartment using high strength doublesided tape between the two compartment halves or high strength single-sided tape around the outside of the compartment.

8. Make sure the taped seam of the compartment faces the downward side of the wire harness.

9. Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located. Make sure the battery wires are not stretched tight.

Gauge Cleaning

1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth.

2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or protective rubber boot. Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source.

NOTICE: To prevent damage to the lens, do not use alcohol for cleaning. Do not

allow chemicals or sprays to contact the lens. Immediately clean off any gasoline that splashes on the gauge during refueling.

Page 52

THE PERFECT FIT

General Representation

IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for approximately 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 snowmobile 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

• Toe (ski alignment) (see page

108)

• Camber (see your dealer)

Front Shock Spring Preload

The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempting to adjust preload.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension.

Decreasing the spring preload too much may allow the lower spring retainer to fall off.

Page 53

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, cargo weight, riding style, trail conditions and vehicle speed all affect suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.

Make adjustments to one area at a time so you can evaluate the change. For further assistance, please see your Polaris dealer.

Suspension Performance Tips

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

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

• In deep snow , a new rail slide wi ll offer improved performan ce over a

worn slide. It can also improve top speed.

• 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 suspension lubrication information beginning on page 82.

Page 54

THE PERFECT FIT

No RiderWith Rider

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

T ake the first measurement with no ri der and with the rear suspension at full extension.

Tip: The rear bumper may need to be raised slightly to fully extend the rear sus-

pension.

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, common ly referred to as ride-in, subtract measurement Y from X (sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. See page 51.

The ideal amount of sag for this rear suspension is 2.5 inches (6.4 cm) (X-Y=2.5 in./6.4 cm).

Page 55

THE PERFECT FIT

Soft Medium Firm

Rear Suspension Adjustments

Torsion Spring Preload

T o adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This adjustment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of adjustment, and follow the steps below carefully.

WARNING! A sudden release of tension from a spring could result in serious injury. Wear eye protection and maintain a firm grip on the spring when removing and installing it.

1. Grasp the spring firmly with both hands.

2. Maintain a firm grip on the spring and carefully remove the long leg from the guide block. Be prepared for a sudden release of tension.

3. Carefully allow the leg to unwind and relieve tension from the cam.

4. Rotate the cam to the desired setting.

5. Rewind the long leg of the spring. Maintain a firm grip on the spring while reinstalling it into the guide block.

Tip: Different rate torsion springs are available if a firmer ride is desired. Contact

your dealer for more information.

The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.

Soft (long end of cam to front) Medium (short end of cam up) Firm (long end of cam up)

Page 56

THE PERFECT FIT

High

Low

Rear Suspension Adjustments

Limiter Strap Position (Ski Pressure)

The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding

style. High: Limiter strap in high

position Low: Limiter strap in low

position decreases ski pressure

increases ski pressure

Page 57

THE PERFECT FIT

Rear Suspension Adjustments

Shock Compression Valving

The rear track shocks for this model are gas charged shocks. The valving on the gas charged shocks is pre-set.

Page 58

THE PERFECT FIT

Handlebar

Cover

Adjuster

Block

Bolts

Nuts

Mountain

Bar

Handlebar Adjustments

Use the following steps to adjust handlebar angle at the handlebar block.

1. Remove the mountain bar.

2. Remove the handlebar cover.

3. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block. Turn the handlebar to the left or right for access to the back nuts. If necessary, pry the blocks apart with a screwdriver.

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

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

6. Reinstall the handlebar cover.

7. Reinstall the mountain bar.

Page 59

THE PERFECT FIT

Accessories

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

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others This applies, but is not limited to the following areas: brakes, clutches,

fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service.

Page 60

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items.

Item See Page

Drive Belt Condition 98 Steering System 58 Brake Fluid 59 Brake Lever/Parking Brake Lock 59, 60 Brake System 91 Throttle Lever 57 Throttle Safety Switch 57 Auxiliary Shut-Off Switch (Engine Stop Switch) 63, 72 Ignition Switch 63, 68 Taillight/Brakelight/Headlight 63 Coolant Level 88 Gearcase Oil Level 81 Injection Oil Level 70 Radiator/Cooling Fins (clean and remove any debris) -Suspension Mounting Bolts 62 Skags (Wear Bars) 62, 109 Ski Saddle and Spindle Bolts 62 Hood Straps/Latches 58 Seat Latches 57 Rear Wheel Idler Bolts 62, 105 Track Alignment/Condition 61, 106 Rail Slide Condition 106

Page 61

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

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

Read and Understand Your Owner's Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

T est the throttle safety switch system before the snowmobile is operated. See page 72 for procedure.

n Seat Latch

Page 62

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hood Latches

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

n Steering System

WARNING! Ice and snow build-u p may interfere with the steering of your

snowmobile, which could cause loss of control resulting in serious injury or death. Keep the underhood area free of snow and ice.

Page 63

PRE-RIDE INSPECTIONS

1/2" (1.3 cm)

Sight

Glass

Master

Cylinder

Before Starting the Engine

n Brakes

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

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2" (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. See pages 91-93 or see your dealer for service.

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Check for the presence of air in the fluid system. See pages 91-93 or see your dealer for service.

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.

n Brake Fluid

Check the brake fluid in the master cylinder before each ride.

V iew the brake fluid level through the sight glass on the top of the master cylinder. The eye will appear dark when the fluid level is full. If the sight glass is any color other than black, add brake fluid. See page 92.

Page 64

PRE-RIDE INSPECTIONS

Brake Lever

Parking Brake

Lever Lock

Before Starting the Engine

n Parking Brake Lever Lock

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

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

Lock Release

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

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

Page 65

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Track Inspection

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.

WARNING! 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.

Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

Page 66

PRE-RIDE INSPECTIONS

Before Starting the Engine

n 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 105 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 106 Track Tension 104 All rear suspension components Lubrication 83 Ski runner/skag Condition -Ski spindle bolts Tightness -Tie rod end nuts Tightness --

Page 67

PRE-RIDE INSPECTIONS

St art the Engine and Check

n Engine Stop Switch

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

n Ignition Switch

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

n Lighting

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

n Mirror Adjustment

If equipped, adjust your mirrors so they can be used to their full advantage.

n Operating Area

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

Page 68

OPERATION

WARNING

Fuel Safety

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 refu-

eling 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.

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.

Page 69

OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free snowmobile 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 vehicle 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 snowmobile.

Page 70

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil bottle when refueling. See page 70.

NOTICE: Serious engine damage can occur without th e proper lubrication.

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES Gold Plus Synthetic 2cycle oil for this engine. See page 116 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.

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

Page 71

OPERATION

Starting the Engine

1. Turn the key to the ON position.

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

2. Pull the engine stop switch up to the RUN position.

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

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

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

5. If the engine does not start after several attempts, slightly depress

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

NOTICE: Operating the vehicle immedi ately after cold starting could cause

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

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

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

snap back into the housing. Damage may result.

the throttle (no more than 1/4I open) while cranking the engine. When the engine starts, immediately release the throttle.

engine damage. Allow the engine to warm up for several minutes before operating the vehicle. If cold drive-away is attempted, the engine RPM may stumble slightly to protect the engine.

Page 72

OPERATION

Restarting an Engine

If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure:

1. Push the engine stop switch down to the OFF position.

2. Turn the key to the OFF position.

3. With both switches OFF, squeeze and hold the throttle in the wide open position.

4. Crank the engine several times to clear the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

n Stopping the Snowmobile

The following chart lists methods for stopping the snowmobile. See page 72 for more information about the engine stop switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All

THROTTLE

CONDITION

Fuel

For peak performance, Polaris recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol. Never use E85 in your snowmobile).

NOTICE: Operating with obstructed fuel systems will result in serious engine NOTICE: Prolonged exposure to petroleum based products may damage paint.

damage. Always perform maintenance as recommended. Always protect painted surfaces when handling fuel.

Page 73

OPERATION

10% ETHANOL

24 OHM

NON-ETHANOL

160 OHM

Resistor

Fuel Resistor

This snowmobile is equipped with a feature that allows the engine controller to select the proper operating software based on the type of fuel being used. The proper fuel resistor must be installed to match the type of fuel you are using.

The snowmobile comes from the factory with the resistor installed that should be used when running fuel containing up to 10% ethanol.The resistor is labeled “10% Ethanol 24 OHM”. A picture of the resistor is shown below. The resistor is installed into the wiring harness on the left side of the snowmobile just above the top of the oil bottle.

If the snowmobile is run with non-ethanol fuel be sure to install the resistor labeled “Non-Ethanol 160 OHM. This resistor is provided in the tool kit.

NOTICE: Engine damage may occur if ethanol

fuel is used while the non-ethanol fuel resistor is installed. The machine may also display the check engine light in this condition as this could cause detonation.

If you are unsure of the type of fuel you are using, make sure the “10% Ethanol 24 OHM” resistor is installed. This is the preferred default and will provide the most engine protection.

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled non-oxygenated), 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 damage resulting from fuel system icing. Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 116 for the part numbers of Polaris products. If you use fuel with up to 10% ethanol (sometimes labeled oxy-

genated) do not add deicers or additives that contain any form of alcohol.

Page 74

OPERATION

“Add”

Mark

n Oil

Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. If oil is not visible, continued operation may cause serious engine damage. Add oil before further operation of the snowmobile.

Low Oil Level

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

Always check the oil level when refueling. When the oil reaches the low level mark, add one quart (.9 liters) of recommended oil to the tank. See page 66 for oil recommendations.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 66 for oil recommendations.

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

1. Immediately stop the engine if the low oil indicator light comes on.

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

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

Page 75

OPERATION

WARNING

Track Warm-Up

A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable.

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 approximately 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 snowmobile to the ground.

5. Grasp the skis by their front loops and move them from side to side to loosen snow and ice.

Page 76

OPERATION

Stop Switch

n Engine Stop Switch

Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting.

n Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position. Test the throttle safety switch system daily before operation.

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.

Page 77

OPERATION

n 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 speed limits at 2400 RPM when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and throttle body 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.

Page 78

OPERATION

WARNING

Electronic Reverse (PERCt)

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase 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.

Engaging Reverse

Tip: Electronic reverse will activate only if the engine RPM is below 4000.

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 transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in

reverse.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.

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

2. Push the yellow reverse button for one second and release. The

3. Apply the throttle slowly to make sure the transmission is in for-

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

engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

ward.

Page 79

OPERATION

Daily Storage

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

Remove the key and cover the snowmobile.

Towing

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.

Page 80

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

Page 81

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 131.

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 check s 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 compone nts 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.

Page 82

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)

Clutches 97 IIII Drive Belt 98 CCC Belt Tension -- IIII Clutch Sheaves 99 IIII

Engine Mounts -- IIII Recoil Rope -- II II Cylinder Head Bolts -- III Cylinder Base Nuts -- III I Ignition Timing BTDC -- III VES System -- CCC I Coolant Level 88 IIRI Coolant Hose -- IIII Coolant Circulation -- III Coolant Leaks -- II II Spark Plugs 84 IIIRI Exhaust Pipe 87 II Exhaust Retaining

Springs

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

Page

150 mi.

(240 km)

97 III

ENGINE/COOLING

87 IIII

(800 km)

CLUTCH

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Page 83

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- IIII Hose Condition -- IIII Fluid Leaks -- IIII Brake Pads 91 IIII Brake Disc -- IIII Parking Brakes 60 IIII Brake System 59, 91 I Brake Fluid 59 R

Idle RPM -- III Throttle Lever 57, 73 III II Oil Pump Lever

(synchronize) Throttle Cable 82 LL L Throttle Position Sensor -- III Fuel Lines 86 II I I I Fuel Filter 86 RR Oil Filter 87 RR Oil Lines -- III Air Box -- III II

Auxiliary Shut-Off Switch

Throttle Safety Switch 72 III II Ignition Switch -- III II Taillight 63 III II Brakelight 63 III II Headlight 63 III II

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- III

ELECTRICAL

63 III II

BRAKES

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Page 84

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- III Suspension Mounting

Bolts Steering Fasteners -- III IC Rear Suspension

Fasteners Drive Shaft Bearing 82 LLL I Skags (Wear Bars) 109 III II Ski Saddle/Spindle Bolts -- III I I Hood Straps 58 III II Rear Wheel Idler Bolts

and Nuts Camber Alignment -- III Handlebar Centering -- I Track Alignment 106 III II Track Tension 104 II I I I Front Limiter Strap -- III II Rail Slide Condition 104 I Gearcase Oil 81 IRI RI

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

Page

150 mi.

(240 km)

-- III II

105 III II

(800 km)

CHASSIS

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Page 85

MAINTENANCE

Lubrication

n Gearcase Oil Level

Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 77. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

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

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

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 116 for the part numbers of Polaris products.

NOTICE: Mixing brands or using non-recommended lubricants could result in

excessive wear to chain, sprockets and bearings. Always use Polarisrecommended products for your vehicle.

Page 86

MAINTENANCE

Driveshaft

Transmission

Lubrication

Throttle Cable

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

Front Suspension

The front suspension and steering components do not require lubrication.

Coupler Lubrication

Using a needle-point grease gun, grease the driveshaft coupler only. The jackshaft on this model is a one-piece jackshaft that requires no lubrication.

Page 87

MAINTENANCE

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 78 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.

Page 88

MAINTENANCE

Spark Plugs

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

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

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-20 ft. lbs. (24-27 Nm).

Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. If a plug is fouled, replace the plug with a new plug.

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

damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile.

Page 89

MAINTENANCE

Spark Plugs

Normal Spark 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.

Tip: The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect throttle body adjustments.

Wet Fouled Spark 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 or rich fuel mixture.

Page 90

MAINTENANCE

Intake Filter

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 with

Fuel Pump

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

Fuel Filter/Fuel Lines

See your Polaris dealer for replacement of the 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

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

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

Page 91

MAINTENANCE

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 the

direction of flow through the filter.

Exhaust System

Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 78.

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. Allow the engine and exhaust system to cool completely.

2. Open the hood.

3. Inspect the muffler and pipes for cracks or damage. Check for weak

or missing retaining springs or damper/support grommets.

4. Replace any damaged or missing components.

5. Clean the plastic surfaces next to the muffler with aerosol Carbure-

tor and Throttle Body Cleaner. See pa ge 1 16 for the part numbers of Polaris products.

6. Close the hood.

Page 92

MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required.

Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 116 for the part numbers of Polaris products.

Tip: Never add tap water to the cooling system. Minerals cause deposits and

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

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

CAUTION! Steam and hot liquids will cause burns to your skin. Never remove the pressure cap when the engine is warm or hot.

n Coolant Level

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

• Coolant recovery bottle

• Coolant reservoir

• Pressure cap

• Connecting hoses

Always maintain the coolant level at the “COLD FILL” mark on the coolant recovery bottle (when the engine is cold).

NOTICE: Operating the snowmobile with insufficient coolant will result in

overheating and serious engine damage. Always maintain the coolant level as recommended.

Page 93

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service.

Add coolant if the level is low. Engine performance will be reduced if you continue operating when the high temperature light is on.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added. Have your Polaris dealer perform this service.

Page 94

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the

cooling system or remove the pressure cap when the engine is warm or hot.

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

NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or

Perform the bleeding procedure when the engine is cold.

1. Position the vehicle so that the top of the tunnel is level. Elevate the

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

3. Remove the bleed screw from the water outlet manifold and/or the

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

5. Start the engine and run at a fast idle for two to three minutes.

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

7. Feel the heat exchangers under the running boards. If the system is

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

engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.

front of the vehicle slightly if necessary.

mixed coolant to the maximum mark.

thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

Loosen the bleed screw occasionally to purge any trapped air.

bled properly , they'll be warm to the touch. If they 're not, repeat step

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

machine.

Page 95

MAINTENANCE

Brake Disc

Backing

Plate

Brake Pad

Material

Gearcase

Brake

Caliper

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 59.

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16" (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. 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" (1.5mm).

Brake Components

• Brake Caliper

• Gearcase

•Brake Disc

• Backing Plate

• Brake Pad Material -

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

Page 96

MAINTENANCE

WARNING

Sight

Glass

Master

Cylinder

Brakes

n Brake Fluid

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.

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

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

up spills immediately.

Check the brake fluid in the master cylinder before each ride.

1. Position the handlebars so the

master cylinder is level.

2. Remove the master cylinder

cover.

3. Add DOT 4 brake fluid only. Do not overfill. See page 116 for the

part numbers of Polaris products.

Page 97

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

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 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" (.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 59.

8. Reinstall the gasket and cover.

Page 98

MAINTENANCE

Spring

Harness

Bulb

Lights

Removing Halogen Bulbs

Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi-

due, 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.

1. Remove the plenum cov-

ering from the headlight assembly. Lift the rubber boot to expose the bulb.

2. Push down on the spring

to release it from the housing.

3. With the wire harness

attached to the bulb, withdraw the bulb from the housing.

4. Grasp the bulb by its

metal base and carefully separate the bulb from the harness.

Page 99

MAINTENANCE

Lights

Installing Halogen Bulbs

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

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. Adjust headlight aim. See page 31.

Replacing Taillight Bulbs

1. Remove the screws securing the taillight cover and remove the

cover.

2. Remove the taillight lens.

3. Push the bulb in and twist it counterclockwise to remove it.

4. Install the new bulb.

5. Reinstall the taillight lens.

6. Reinstall the taillight cover.

Page 100

MAINTENANCE

Electrical System

RELAY LABEL FUSE LABEL ITEM POWERED

START SOLENOID RELAY

SPARE 20A None ACCESSORY

EMERGENCY

CHASSIS RELAY

EFI RELAY

IGNITION RELAY PTO ignition coil

FUEL PUMP RELAY Fuel pump FAN RELAY Radiator fan

SPARE 30A

CHASSIS 30A

EX. SENSOR GAUGE 20A

IGNITION 20A Ignition relay power

EFI 20A

Ground side of start solenoid

Accessory plugs

High beams Low beams Handwarmers Thumbwarmer Passenger handwarmers Work light Tail lamp Brake lamp Alternator coils Exhaust sensor Gauge Accessory projector beam relay Diagnostic plug

Cam phase sensor ECU hold-on power Forward limit switch Start relay coil Chassis relay coil Ignition relay coil Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injector MAG injector

MAG ignition coil