Polaris 800 Pro X User Manual

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.

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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)

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