Polaris 800 Pro X User Manual

Download

2004

PRO X

Snowmobiles

Owner's Manual

for Vehicle Maintenance

and Safety

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.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

What’s the hottest thing on snow?

A Polaris owner’s Web site, designed just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

WELCOME

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

Polaris Recreational Vehicles

S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)

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

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

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

We also take great pride in our Parts Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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

WORKMOBILES, UTILITY TASK VEHICLE and PERSONAL TASK VEHICLE are trademarks of Polaris Industries Inc.

TABLE OF CONTENTS

Introduction 7...............................

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 10....................................

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

Features and Controls 28.....................

This section illustrates t he locations of your snowmobile’s controls and features.

The Perfect Fit 32............................

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

Pre-Ride Inspections 48......................

This section explains procedures that must be performed before riding.

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

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

Maintenance 69..............................

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

Polaris Products 1 12.........................

T roubleshooting 1 13.........................

This section is a quick reference guide to solving problems.

Warranty 118................................

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

INTRODUCTION

Important Notes for Owners and Drivers

n After reading this m anual, store it in the snowmobile for

convenient reference. It should remain with the snowmobile when sold.

n The illustrations and photos used in this manual are general

representations. Your model may differ.

n Follow the maintenance program outlined in this manual.

Preventive maintenance ensures that critical components of the snowmobile are inspect ed by your dealer at specific mileage intervals.

n 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.

n Protect and preserve your right to ride by joining your local trail

riding clubs.

INTRODUCTION

Preservation of the Environment

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

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

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

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.

INTRODUCTION

Vehicle Identification Numbers

The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these numbers are essential to its recovery and identification.

Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a P olaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer.

NOTE: Record your snowmobile’s ID numbers and key number in the spaces provided.

Tunnel VIN (lower right side of the tunnel) :

Vehicle Model Number:

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

Key Number:

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

Operator Safety

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

Polaris produces high performance snowmobiles capable of traveling at high speeds. Extra caution must be observed to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. We strongly recommend that the operator check major and vital safety components before every ride.

All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile.

SAFETY

Operator Safety

Stay Away From Moving Parts

WARNING

Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.

We recommend having your dealer perform track service and alignment procedures.

Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track.

WARNING

If fingers or clothing contact the moving parts of an engine, serious injury can result. Always stop the engine before attempting adjustments.

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.

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.

SAFETY

Operator Safety

Riding Position

WARNING

Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle.

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably positioned for proper throttle, brake, and steering control.

Riding Apparel

Be aware of the weather forecast and especially the wind chill. A wind chill table is provided on page 22 for your reference. To better enjoy your ride, be prepared, be warm and be comfortable.

WARNING

Loose clothing or long scarves may easily become entangled in moving parts and cause serious personal injury.

Always wear an approved helmet and eye protection.

Disabled Operators

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

SAFETY

Operator Safety

Excessive Speed

WARNING

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

Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.

Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet . If your speed is 60 MPH, your machine will travel about 180 feet in two seconds.

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

Ice and Snow Build-up

WARNING

Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Snow screens and bib kits are available through your dealer to help reduce snow and ice build-up.

SAFETY

Operator Safety

Driver Awareness

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

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

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

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

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.

If you must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops, or other people or vehicles that may be on the other side of the hill.

If you’re unable to continue up a hill, turn the machine downhill before it loses momentum. If this isn’t possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the parking brake (if equipped). Keeping away from the downhill side of the machine, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the machine, restart the engine, release the parking brake, and descend the hill carefully.

SAFETY

Operator Safety

Driving Down hill

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

WARNING

When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

Clutch Guard

Do not operate the engine with the clutch guard removed.

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

Drive Belt

Do not operate the engine with the drive b elt removed.

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

SAFETY

Operator Safety

Powder Snow Operation

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

WARNING

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

Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

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

CAUTION

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

SAFETY

Operator Safety

Driving on Slippery Surfaces

WARNING

Driving on ice or hard-packed snow reduces steering and braking control, which may result in serious injury or death. Slow down and use caution.

Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions.

It’s dangerous to drive on ice or other slippery surfaces. If it’s unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction. The chance of “spin-out” increases under these conditions.

Intake Silencer

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

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

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the machine into motion, but always operate within safety limits and, on 2-Up machines, with respect for a passenger. See Starting a Cold Engine on page 53.

SAFETY

Operator Safety

Maneuverability

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

Maintenance

Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 69 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Rider Capacities

Polaris PRO X snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. See page 24 for decal location.

SAFETY

Operator Safety

Driving Responsibly

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

S A snowmobile depends on the rider’s body position for proper bal-

ance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

S Before allowing someone else use your snowmobile, know the ex-

tent of their operating skills. Check to see if they’ve taken a snowmobile safety course and have an operator’s certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

S Don’t “jump” your snowmobile. Jumping may injure your back be-

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

S Be courteous to oncoming traffic by dimming your headlights and

reducing your speed. Your snowmobile is equipped with a high output headlamp system that may cause discomfort to operators of oncoming vehicles when on high beam.

S When traveling in a group of snowmobiles, don’t tailgate (follow too

closely). Allow ample stopping distances, and keep track of those following you. Drive defensively to avoid accidents.

S Remove the key from the ignition.

SAFETY

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Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Estimated Wind

Speed in MPH

Calm 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

5 48 37 27 16 6 -5 -15 -26 -36 -47 -57 -68

10 40 28 16 4 -9 -21 -33 -46 -58 -70 -83 -95

15 36 22 9 -5 -18 -36 -45 -58 -72 -85 -99 -112

20 32 18 4 -10 -25 -39 -53 -67 -82 -96 -110 -124

25 30 16 0 -15 -29 -44 -59 -74 -88 -104 -118 -133

30 28 13 -2 -18 -33 -48 -63 -79 -94 -109 -125 -140

35 27 11 -4 -20 -35 -49 -67 -82 -98 -113 -129 -145

40 26 10 -6 -21 -37 -53 -69 -85 -100 -116 -132 -148

Wind Speeds Great-

er Than 40 MPH

Effect

50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

Little Danger

(For Properly

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

WIND CHILL CHART (°C)

Estimated Wind Speed

inKPH

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

10 1 -4 -11 -16 -22 -27 -33 -38 -45 -50

20 -4 -9 -17 -23 -29 -36 -42 -48 -54 -61

30 -7 -13 -21 -28 -35 -42 -48 -55 -63 -69

40 -9 -16 -24 -32 -39 -47 -53 -61 -69 -76

50 -11 -18 -26 -34 -41 -49 -57 -64 -73 -80

60 -12 -19 -27 -35 -43 -51 -59 -66 -75 -82

70 -13 -20 -28 -36 -44 -52 -60 -68 -76 -84

Wind Speeds Greater

Than 70 KP H Have Little

dded E

ect

Actual Thermometer Reading (°C)

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

Equivalent Temperature (°C)

Little Danger

(For Properly

lothed Person

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

SAFETY

Safety Decals and Locations

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

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

Clutch Cover Warning

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

WARNING AVERTISSEMENT

Air Box Warning

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

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

Pressure Cap Warning

This warning decal is found on the coolant bottle cover of liquid cooled models:

CAUTION

7075351

SAFETY

Safety Decals and Locations

Track Warning

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

Passenger Warning

Polaris PRO X snowmobiles are designed for one operator only. A “No Passenger” warning decal is located on the console:

Safety Decals and Locations

Reverse Warning

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

WARNING AVERTISSEMENT

SAFETY

Safety Decals and Locations

Operation Warning

Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English.

WARNING

Safety Decals and Locations

Operation Warning

AVERTISSEMENT

SAFETY

FEATURES AND CONTROLS

Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on the following pages. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of specific features on your machine. Accessories are available from your Polaris dealer.

1. Brake Lever

2. Speedometer 3 Reverse Indicator Light

4. Tachometer 5 Temperature Light

6. Engine Stop Switch

7. Throttle Control

8. Choke Control

9. Recoil Starter Handle

10. Fuel Filler Cap

11. Park Brake Lock

12. Headlight Dimmer Switch

13. Electronic Reverse Button

14. Handlebar Grip Warmer/ Thumbwarmer Switch

15. Ignition Switch

16. Tether Switch (accessory)

FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Storage Compartment/Trunk

7. Taillights

8. Rear Bumper

9. Snow Flap

10. Track

1 1. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper

15. Skis

FEATURES AND CONTROLS

Detonation Elimination Technology (D.E.T.)

Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing. When activated, the “DETONATION FLASH” indicator (A) will flash in the lower right-hand area of the tachometer. The activated sensor reduces engine detonation by ret arding the ignition timing. This results in decreased engine RPM and performance.

D.E.T. Troubleshooting

Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer.

Possible Cause Solution

Poor quality fuel Replace with higher quality fuel

Improper jetting Verify and adjust per jetting chart

Improper engine modifications Do not modify the engine

D.E.T. Flash Signals

Use this chart to determine the meaning and course of action for each D.E.T. flash signal.

Type of Flash Cause Action

3 flashes of 1 second each

Solid 3-second flash, off 1 second, repeats until engine is shut down

Solid non-blinking light High water tem-

Detonation See DET Troubleshooting Chart

Faulty sensor See your Polaris dealer

perature

See your Polaris dealer. NOTE: If temporary operation is unavoidable, drive slowly and stop the engine frequently to allow the engine to cool.

THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before making any fine-t uning adjustments.

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

Independent Front Suspension (IFS)

The IFS is made up of the skis (1), front shocks and springs (2), and the components that connect these parts to both the steering, such as the tie rods (3), and to the machine itself, such as the trailing arms (4). Front suspension adjustments include shocks, springs, toe, and camber.

NOTE: Although the front suspension on your machine may not look exactly like the illustration, it will have the same parts and functions as those illustrated.

IFS Adjustment Options

S Front shock spring preload S Compression adjust clicker (if equipped) S Optional springs S Optional shock valving (if equipped with RydeFX or Walker/Evans

shocks)

S Toe (ski alignment) (see page 105) S Camber (see your dealer)

THE PERFECT FIT

Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page105 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

The tension at which the shock coil spring is set is called spring preload. F or the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. To determine if your machine is using full travel of the ski shock, push the jounce bumper down as far as it will go on the shock rod and test ride the machine. The bumper will move up on the rod in direct relation to the amount of travel. If the shock travel is full, the bumper will be seated at the top of the shock.

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper (RydeFX only)

4. Body

5. Threaded Spring Preload Adjuster Nut

THE PERFECT FIT

Front Suspension Adjustments

Adjusting Front Shock Spring Preload

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

To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload. In the illustrations at right, B indicates high preload and C indicates low 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 upper spring retainer to fall off. Always leave at least one thread showing above the nut (A).

THE PERFECT FIT

Front Suspension Adjustments

Shock Valving

RydeFX and Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness.

WARNING

Changing shock valving on RydeFX or Walker/Evans shocks requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer.

Front Springs

For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.

THE PERFECT FIT

Rear Suspension Adjustments

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

Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments i nvolve 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.

A decal outlining rear suspension set-up options is located either under the hood or on the clutch cover. It provides a guideline for initial suspension set-up. Additional adjustments can be made from t his point. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see your dealer.

Suspension Performance Tips

S 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.

S A new Hi-fax will offer improved performance over a worn Hi-fax.

It can also improve top speed.

S When riding on ice or hard-packed snow, adding a set of bogie

wheels to the rail may enhance the machine’s performance. Bogie wheel kits are available from your dealer.

S Polaris offers track kits for improved flotation in deep snow. S ee

your dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. Refer to Suspension Maintenance beginning on page 107.

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

Take the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.

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

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration or the decal found under the hood for reference. The ideal amount of Sag for the PRO X rear suspension is five inches (X-Y=5).

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

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Rear Torsion Spring Tension

To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug t ool. 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.

1a - Turn the knob to the left for a softer ride 1b - Turn the knob to the right for a stiffer ride 2a - Soft Tension - long end of cam to front 2b - Medium tension - short end of cam up 2c - Firm tension - long end of cam up

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Clicker Shock

The position sensitive clicker shock is available as an option on some models. Adjustments to the compression damping are made by turning the clicker knob (A) on the shock reservoir.

Position #1 is the softest, or least compression damping. As the knob is turned to higher numbers, compression damping increases, or becomes stiffer.

When adjusting, we recommend that you turn the clicker only one click at a time, then test ride.

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Optional Coil Springs

Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information.

Suspension Coupling

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

Front Rear Scissor Stop (FRSS)

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

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

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Rear Rear Scissor Stop (RRSS)

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

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

Rear Rear Scissor Stop - Attributes

Moving the RRSS to a higher position, or forward hole, will have the following effects on the suspension:

S Reduced weight transfer. S Improved chatter bump ride. S Improved cornering performance.

THE PERFECT FIT

PRO X Rear Suspension Adjustments

Weight Transfer During Acceleration

PRO X Rear Rear Scissor Stop (RRSS)

The preferred method for controlling weight transfer during acceleration of the PRO X rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your tool kit to make the adjustments.

T o decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.

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

A - Low Position - This setting will increase weight transfer. B - Medium Position - This setting is the production setting and will

provide the best overall trail riding. C - High Position - This setting will decrease weight transfer. D - Rearward Upper Position (optional hole location) - This setting

will increase weight transfer. NOTE: Your dealer can help you with initial set-up and additional

set-up instructions to help you achieve an optimum ride.

THE PERFECT FIT

Handlebar Adjustments

Handlebar with Riser Block

1. Remove the handlebar cover to expose the handlebar mounting hardware.

2. Using a 1/2” wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required.

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

4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-17.6 Nm).

5. Replace the handlebar cover.

THE PERFECT FIT

Accessories

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

NOTE: The accessory tether switch is available for all models. Order PN 2870668.

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

S Non-compliance with government/industry requirements S Voiding of warranty S Personal injury to self or others

This applies to, but is not limited to brakes, clutches, fuel systems, and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use ap- proved Polaris parts. Please see your Polaris dealer for service.

THE PERFECT FIT

Accessories

Traction Products

Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.

NOTE: Before equipping your machine with traction products, be aware of t he laws in your area pertaining to the use of traction products.

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

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control. Similarly, if your machine is equipped with carbide skags or you’re adding them, it may be necessary to add track studs to maintain proper vehicle control. Proper balance must be maintained between the number of studs and the length of carbide on skags. The more studs used, the longer the carbide on the skags should be. See your dealer’s track studding chart for recommended studding and skags.

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

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

THE PERFECT FIT

Accessories

CAUTION

Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8″ (2.86 cm) from outside edge of the track.

CAUTION

If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear.

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

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

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

WARNING

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

THE PERFECT FIT

Accessories

Wear Strips

Polaris PRO X models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used.

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

Components as viewed from the rear of the track:

1. Top of tunnel

2. Wear strip

3. Track

4. Wearstrip mounting holes

CAUTION

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING

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

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.

Check Throttle and Brake for Proper Operation

The throttle and brake are the primary controls of your snowmobile. If either should malfunction, loss of control could result.

Make sure the throttle lever compresses evenly and smoothly. The lever should immediatel y return to the idle position without binding or hesitation. If the throttle does not function smoothly, DO NOT start the engine. Have the throttle serviced immediately.

The need for a properly functioning brake is critical. Your snowmobile is equipped with the highest quality brake system available. Check the brakes for correct operation before starting the engine.

Throttle Safety Switch

Test the throttle safety switch system daily, before the machine is operated.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Hydraulic Brakes

Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine.

Brake Lever Travel

When the brake lever is squeezed, it should move no closer to the handgrip than 1/2″ (1.3 cm) (A). A distance less than this indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 93.

Lever Feel

A hydraulic system multiplies t he force of your hand squeezing the brake lever. Proper operation depends on an adequate supply of air and moisture-free hydraulic brake fluid in the system. If the brake lever feels “spongy” when squeezed, check the level and condition of the fluid. Also check for the presence of air in the fluid system. Refer to page 93 for more information, or see your dealer for service.

Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris brake fluid. See page 112 for the part numbers of Polaris products.

WARNING

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

Park Brake Lever Lock

Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. T o apply the lock, squeeze the brake handle and push forward on the brake lever lock. Hold the lock forward and release the brake handle.

If the brake handle is squeezed tightly enough, the lock will move freely into place. Do not force the lock or it may break. To release the lock, squeeze the brake handle until the lever returns to the unlock position. The park brake light on the console will light up when the park brake lever lock is set and the engine is running. It will also be lit when the service brake is in use. If the park brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer.

1. Brake Lever

2. Park Brake Lever Lock

3. Master Cylinder Reservoir / Cover

WARNING

If the park brake lever lock is partially or entirely engaged while riding, overheating of the brakes could occur, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Check for Proper Operation o f Steering System

Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

Track Inspection

WARNING

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

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.

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

Check for Securely Latched Hood

The hood of the snowmobile protect s 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.

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch: Check the auxiliary shut-off switch for

proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine.

n Tether Switch: If your machine has a tether switch, make sure the

engine shuts off when the tether is removed from the switch.

n Lighting Check: Check the headlight (high and low beam),

taillight, and brake light for normal operation.

n Mirror Adjustment: If equipped, adjust your mirrors so they can

be used to their full advantage.

n Check Surroundings to Verify Clear Operating Area

Make sure you have a clear area all around your snowmobile, including an area cl ear of bystanders. There’s always the possibility of some sideways vehicle movement, of applying a little more throttle than intended, or of debris being thrown by the track. If the surrounding area is clear you before you start, you can devote your full attention to operating the snowmobile.

OPERATION

CAUTION

Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads.

Starting the Engine

WARNING

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 48.

Starting a Cold Engine

Do not depress the throttle until the engine starts.

1. Turn key to ON.

2. Pull kill switch (shut-off switch) up to RUN.

3. Flip choke toggle to FULL ON.

4. Grasp starter handle and pull slowly until recoil engages; then pull abruptly to start the engine.

CAUTION

Don’t pull the starter rope to full extended position or allow it to snap back into the housing. Damage may result.

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

5. After the engine starts, flip the choke toggle to the OFF position. If the engine slows or wants to stop, use intermittent choking to the HALF ON position.

OPERATION

Starting the Engine

Starting a Warm Engine

1. Turn key to ON.

2. Pull kill switch (shut-off switch) up to RUN.

3. Grasp starter handle and pull slowly until recoil engages; then pull to start.

If the engine does not start on the first pull, slightly depress t he throttle with your left hand (no more than 1/4″ open), and pull the rope with your right hand. When the engine starts, immediately release the throttle.

Engine Break-In

No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

CAUTION

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

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

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

OPERATION

Engine Break-In

Oil Injection System

CAUTION

Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately.

Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are controlled by the oil pump and correspond to the engine’s RPM and throttle valve opening.

Variable Exhaust System

We recommend the use of Polaris VES two-cycle oil in all snowmobile engines equipped with vari able exhaust valves (see chart below).

Oil Recommendations

The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems. We highly recommend the use of only Polaris products. We’re continuously testing lubricants and provide the highest performance products available for your snowmobile’s engine. Refer to the table below to determine the recommended oils for use in your Polaris snowmobile.

Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. They may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other.

Engine

Style

Fan Cooled

Liquid Cooled

Liquid Cooled w/VES

Premium

2-Cycle

Good Better N/A

Good Better Best

Premium Gold

2-Cycle

VES

OPERATION

WARNING

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

WARNING

Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.

Track Warm-Up

Follow these steps to ensure proper warm-up

of the engine, drive train and track.

1. Use an appropriate stand to securely support the rearof the snowmobile atthe 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. NOTE: It will take longer to warm up the track sufficiently during colder outdoor temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower the machine to the ground.

5. Grasp the skis by their front loops and move them from side to side. This will loosen frozen snow from the ski bottoms, allowing the machine to move forward more easily.

6. The engine, drive system and track are now properly warmed up and the machine may be driven following normal safety practices.

OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a

well ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S 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.

S Turn the fuel valve off whenever the snowmobile is stored or

parked.

WARNING

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

Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Fuel

The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris snowmobile engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline, but a higher octane fuel (premium 91 octane) is preferred for the PRO X models. Always use the premium fuel switch when using premium fuel in your machine.

Premium Fuel Switch

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

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

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

CAUTION

Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine.

OPERATION

Fuel

Fuel Reserve Capacity

There are approximately two gallons of fuel left in the tank when the fuel gauge indicates reserve (RES).

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. See page 112 for the part numbers of Polaris products.

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

CAUTION

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

Oil

Low Oil Level

Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 55 for oil recommendations.

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

OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 55 for oil recommendations.

When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank. If oil is not visible, continued operation may cause seri ous engine damage.

Always maintain the oil level above the tank’s l ow level line. This is especially important when the machine is operated in mountainous terrain. Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris VES oil in all snowmobile engines equipped with variable exhaust valves. Never mix brands.

CAUTION

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

OPERATION

Carburetion

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

A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system. Either condition may be caused by improper carburetor adjustment.

WARNING

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

Jetting Gu id elin es

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

Carburetors on most Polaris models are calibrated for an altitude of 0-2000 ft (0-600 meters) and ambient temperatures between -10 to +10 F (-23 to -12 C). All carburetors must be re-calibrated if operated outside this production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures.

CAUTION

A main jet that’s too small will cause a lean operating condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner’s Manual Supplement.

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

OPERATION

Engine Stop Switch

Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position.

Throttle Safety Switch

Test the throttle safety switch system daily before operation. While seated in a normal riding

position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration (B). Apply a slight amount of throttle. A properly functioning switch must shut down the engine.

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

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident. If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

OPERATION

Throttle Lever

WARNING

An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine.

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor(s) to determine what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times. The lever and cable must return to the i dle position quickly and completely.

4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures.

5. If the engine doesn’t start, take the snowmobile to an authorized Polaris dealer for service.

Excessive free play in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness. When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the m achine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 62 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

WARNING

Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system. This overheated condition could cause sudden loss of brakes and/or fire, resulting in serious injury or death.

When traveling on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat and result in brake failure.

OPERATION

Emergency Starting

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

WARNING

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

To use the emergency start strap:

1. Open the clutch guard.

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

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

4. Pull the strap abruptly so the strap comes free of the clutch while starting the engine.

OPERATION

Reverse Operation

WARNING

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.

S Always look behind the vehicle before and while backing. S Always avoid sharp turns. S Shift to or from reverse only when stopped. S Always apply throttle slowly.

Electronic Reverse (PERCt)

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

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

2. Push the yellow reverse button on the handlebar for one second, then release. The engine will automaticallyreduce RPM and start a reverse rotation. A flashing reverselight on the instrument panel will indicate that the machine is in reverse.

3. Slowly apply the throttle until movement starts and you’re sure the machine is in reverse.

NOTE: The maximum engine RPM will be 6000 when in reverse. NOTE: If the engine stops running, the snowmobile will be in for-

ward gear when it’s restarted.

CAUTION

Operating the electric starter or the recoil while the engine is running can result in personal injury and/or engine damage. Do not operate the electric or pull-rope starter while the engine is running.

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Disengaging Reverse

Push the yellow reverse button on the handlebar for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off. Make sure the area around your vehicle is clear and apply throttle slowly until you’re sure the machine is in forward gear.

Altitude Setting

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

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

OPERATION

Towing

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

CAUTION

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

MAINTENANCE

Daily Storage

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

Remove the key and cover the machine. NOTE: Polaris has accessory covers

and track stands available to fit all models. See your dealer for more information.

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual.

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

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

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

Personal safety is critical when attempting to service or adjust 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.

MAINTENANCE

Maintenance Chart

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 Weekly or

Check brake operation and adjustment

Test engine stop switch Daily 52

Test tether strap Daily 52

Test throttle safety switch Daily 48, 62

Throttle lever operation Daily 48, 62

Check operation of headlights, taillight, brakelight

Check park brake function Daily 50

Secure hood Daily 51

Check track alignment X 102

Steering arm and tie rod ends X 104

Throttle cable condition X -

Coolant level X 86

Check track tension X 101

Check chaincase oil level X 77

Check gearcase oil level X 77

Check drive chain tension X 89

Check drive belt condition X 97, 98

Check and tighten loose suspension mounting bolts

Tighten ski saddle and spindle bolts

Check front limiter strap condition, tighten bolts

Check ski skags- replace when worn to half original diameter

Check Hi-fax thickness, replace when worn (Dealer)

Tighten rear idler wheel bolts X 102

Flush Chaincase 77

before

long trip

Daily 48, 90

Daily 52

X -

X 45

X 107

150

miles

(240 km

500

miles

(800 km)

1000

miles

(1600 km)

See

Page

MAINTENANCE

Maintenance Chart

Item Weekly or

Tighten idler adjusting bolt jam nuts

Check spark plug condition X 79

Inspect coolant filter, replace if necessary

Grease ski pivots X X X 74

Grease ski spindles X X X 74

Grease center steering arm(s) X X X 74

Lubricate steering post support bracket and pivot (aerosol)

Check cylinder base stud torque on all Polaris engines. (Specification: 32 ft. lbs ± 2 ft. lbs.) (Dealer)

Grease lower steering post pivot X X X 74

Grease driveshaft bearing (always perform before storage)

Check and drain water trap X X 82

Grease rear suspension pivot shafts

Grease jackshaft bearing (always perform before storage)

Lubricate throttle cable X X 76

Lubricate choke slide and cable X X 76

Check clutch alignment and offset X X 96

Check cooling system level, specific gravity

Inspect oil line condition X 83

Inspect fuel filter and replace X X 83

Check brake fluid level X X 92

Inspect fuel lines and replace X 83

Inspect exhaust system for weak or missing retaining springs

Inspect exhaust pipe for cracks or damage

Inspect clutch sheaves for damage, wear, belt residue

before

long trip

X 101

150

miles

(240 km

X X X 88

X X X 74

X X X -

500

miles

(800 km)

X X 76

X X 75

X X 76

X X 86

1000

miles

(1600 km)

X 85

X 96

See

Page

MAINTENANCE

Maintenance Log

Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.

150 Mile (240 km) Initial Maintenance Inspection