Polaris Edge Snowmobiles 2004, Edge 2005 Owner's Manual

Download

WARNING

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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.

Copyright 2004 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 Personal Watercraft S Sport Boats 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 repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

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

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.

M-10 and M-10 ACE are registered trademarks of FAST Inc.

TABLE OF CONTENTS

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

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.

Safety 8.....................................

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

Features 25..................................

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

The Perfect Fit 30............................

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

Pre-Ride Inspections 58......................

This section explains procedures that must be performed before riding.

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

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

Maintenance 81..............................

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

Polaris Products 134.........................

Troubleshooting 135.........................

This section is a quick reference guide to solving problems.

Warranty 142................................

This section outlines specific warranty information.

Index 148....................................

INTRODUCTION

Important Notes for Owners and Drivers

n After reading this manual, 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 inspected 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 the 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 l ead 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. Your key can be duplicated only by m ating a Polaris 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) :

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

Vehicle Model Number:

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.

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 81 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. 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.

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.

SAFETY

Operator Safety

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment that’s appropriate to the conditions you may encounter. Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone.

For added protection, carry the following items on your snowmobile at all times:

SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SW inter Survival Kit STrail Map SOwner’s Manual SFirst Aid Kit

Riding Apparel

Be aware of the weather forecast and especially the wind chill. A wind chill table is provided on page 20 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.

SAFETY

Operator Safety

Disabled Operators

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

Rider Capacity

Your Polaris snowmobile is designed for a single rider only. A decal on the console indicates single rider operation. See page 22 for decal location.

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.

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

Avalan ch es

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

S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with

a shovel, probe and avalanche beacon.

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

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

For more information about avalanche training and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalanceassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

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

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.

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.

Driving Downhill

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

WARNING

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

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

SAFETY

Operator Safety

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 belt removed.

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

Intake Silencer

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

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

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the machine into motion, but always operate within safety limit. See Starting a Cold Engine on page 64.

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.

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 Responsibly

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

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

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

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

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

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

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

S Be courteous to oncoming traffic by dimming your headlights and

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

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

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

S Remove the key from the ignition.

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Estimated Wind

Actual Thermometer Reading (°F)

Speed in MPH

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

Equivalent Temperature (°F)

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

aveLit

tleAdde

Little Danger

(For Properly

Clo

the

dPers

on)

Increasing

Danger

Great

Danger

HaveLittleAdded

Effect

ClothedPerson

)

Danger From Freezing of Exposed Flesh

WIND CHILL CHART (°C)

Estimated Wind Speed

Actual Thermometer Reading (°C)

inKPH

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

Equivalent Temperature (°C)

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 KPH Have Little

Little Danger

(For Properly

Increasing

Danger

Great

Danger

dded E

ect

lothed Person

)

Danger From Freezing of Exposed Flesh

SAFETY

Safety Decals and Locations

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

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

Clutch Cover Warning

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

Do not operate engine with hood open. Do not attempt adjustment with engine running. Do not operate engine with this guard open. Never run engine with drive belt removed. Never service clutches yourself - see your dealer.

Airbox Warning

This warning decal is found under the hood on applicable models:

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

Pressure Cap Warning

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

Do not open hot. Test or replace when changing coolant. Press down and turn to release cap. 13 PSI

Seat Bucket Warning

The seat bucket warning is molded into the seat bucket mounting flange. It’s visible when the bucket i s removed:

DO NOT OPERATE WITH SEAT BUCKET REMOVED.

SAFETY

Safety Decals and Locations

Track Warning

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

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

Passenger Warning

Some snowmobiles are designed for the operator only, while others are designed for the operator and one passenger. A warning decal on the console indicates whether it’s designed for the operator only (1-Up) or the operator and a passenger (2-Up).

Decal text found on 1-Up Models:

This vehicle is designed for operator only. “NO PASSENGER”

SAFETY

Safety Decals and Locations

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

Reverse Warning

Polaris snowmobiles equipped with electronic reverse have this electronic reverse decal:

Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always:

S Look behind before and while backing. S Avoid sharp turns. S Shift to or from reverse only when stopped. S Apply throttle slowly.

For more information, see your Owner’s Manual. If electric reverse:

S Machine stopped a nd engine at idle, push yellow button on LH

controlto reverse.Flashing lighton dash indicates reverseoperation.

S Push button again to return to forward. S Elevation setting (above 6000 feet): push and hold for longer than

5 seconds to set. Let go of button at desired setting-fast flash for high elevation, slower flash for low. Setting will remain until changed.

SAFETY

Safety Decals and Locations

Operation Warnin g

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

Operation Warning Decal Text:

S To avoid serious injury or death, read and understand all warnings

and the Owner’s Manual before operation. If the manual is missing, contact a Polaris dealer for a replacement.

S This vehicle is capable of high speeds. Buried objects or uneven ter-

rain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.

S Excessive speed, especially at night or with limited visibility, can re-

sult in insufficient time for you to react to terrain changes, to avoid unexpected obstacles, or to stop safely .

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S In an emergency, push down the Auxiliary Shut-Off Switch, located

on the top of the throttle control assembly, to stop the engine. Then pull the brake lever to stop.

S Always wear an approved helmet, eye protection, and adequate

clothing while operating this vehicle.

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

requirements.

S When operating with a passenger (on approved models only) reduce

speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

S When operating on hard-packed snow, ice, or when crossing roads,

steering and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

S To maintain vehicle control on ice or hard-packed surfaces, you

should have a proper balance of ski carbides to track studs. See Owner’s Manual for proper use of traction products.

S Repeated stops from high speed may cause fading or sudden loss of

braking ability.

S Parking brake may relax when used for long periods. Do not leave

brake engaged for more than five minutes.

S Before starting the engine, check throttle, brake, and steering for

proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.

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

FEATURES

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Storage Compartment/Trunk

7. Taillights

8. Rear Bumper

9. Snow Flap

10. Track

11. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper

15. Skis

16. Adjustable Seat Bucket (select models)

FEATURES

Some Polaris snowmobiles are equipped with special features such as a reverse indicator light, electronic fuel gauge, temperature light and electric shock control gauge. Not all models come with these f eatures. Refer to your Owner’s Manual Supplement for the features on your machine.

1. Fuel Filler Cap (with gauge on some models)

2. Ignition Switch

3. Brake Lever

4. Speedometer

5. Tachometer

6. Engine Stop Switch

7. Throttle Control

8. Hood Hold Down Straps

9. Recoil Starter Handle

10. Choke

11. Headlight Dimmer Switch

12. Park Brake

13. Handlebar Grip Warmer Switch

14. Thumbwarmer Switch

15. Electronic Reverse Button

16. Electronic Shock Control Button

FEATURES

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 retarding 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

Detonation See DET Troubleshooting Chart

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

Faulty sensor See your Polaris dealer

Solid non-blinking light High water tem-

perature

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

FEATURES

Adjustable Seat Bucket

On models equipped with an adjustable seat bucket (1), the bucket can be adjusted forward or rearward for rider comfort. The seat bucket is removeable for access to the under-seat storage compartment.

Do not sit on the seat bucket.

Do not operate the snowmobile with the seat bucket removed.

WARNING

Operating or riding the snowmobile with the seat bucket removed or while sitting on the seat bucket may cause loss of control or ejection from the snowmobile, which could result in serious injury or death. Never sit on the seat bucket, and always make sure the seat bucket is securely installed before operating the snowmobile.

Seat Bucket Adjustment

To adjust the seat bucket, press down on the release latch (2) and slide the bucket forward or rearward to the desired position. Make sure the

bucket locks firmly in position before operating the snowmobile.

FEATURES

Trunk Lock

Models equipped with the adjustable seat bucket are also equipped with a trunk lock, which is located between the taillights (1). Use the trunk lock keys to lock or unlock the under-seat storage compartment. If keys are lost or misplaced, see your Polaris dealer.

When the trunk is locked, the lock cannot be pressed in and the seat bucket cannot be removed.

NOTE: If the trunk is locked

after the bucket has been removed, the bucket can still be reinstalled. The lock will remain engaged until it’s unlocked with the key. When reinstalled, the bucket will be locked in place.

Trunk Access

The seat bucket must be removed to access the trunk.

1. Unlock the trunk using the trunk lock key.

2. Press the lock inward and hold while rotating the adjustable seat bucket 1/4 turn.

3. Release the lock and lift the seat bucket to remove it from the seat.

4. To reinstall, place the bucket sideways onto the bucket mounting flange (2). Rotate the bucket 1/4 turn to its original position. Make sure it latches securely.

WARNING

Operating the snowmobile with the seat bucket removed may cause loss of control or ejection from the snowmobile, which could result in serious injury or death. Always make sure the seat bucket is securely installed before operating the snowmobile.

CAUTION

Movement of heavy, loose tools or other objects in the storage compartment may result in damage to the taillights. Always secure any loose objects to prevent bouncing and shifting within the compartment.

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-tuning adjustments.

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

Independent Front Suspension (IFS)

The IFS is made up of the skis (1), front shocks and springs (2), and the components t hat 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 Shock damping (if equipped with Indy Select or RydeFX SOLO

shocks)

S Front shock spring preload S Optional springs S Optional shock valving (if equipped with RydeFX shocks) S Toe (ski alignment) (see page 124) S Camber (see your dealer)

THE PERFECT FIT

Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page 124 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. To determine if your machine is using full travel, push the jounce bumper down on the shock rod until it contacts the body and test ride the machine. The bumper will move up on the rod in relation to t he amount of travel that was used during the ride. If the travel is full, the bumper will be seated at the top of the rod.

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded S pring Preload Adjuster Nut

THE PERFECT FIT

Front Suspension Adjustments

Shock Damping

Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and it should be considered first. A clockwise adjustment will increase stiffness in both styles of shock, but there are some differences.

Indy Select Shock

The factory setting for this shock is the softest position, with the adjusting screw all the way out (counterclockwise). If bottoming occurs, the Indy Select feature should be used to achieve the desired ride. The shocks have a wide range of adjustment capability. B y turning the screw clockwise, the compression of the shock i ncreases, stiffening the ride. When adjusting these shocks, we recommend that you turn the screw only 1/4 turn at a time, then test ride. Always adjust both shocks equally.

RydeFX SOLO Shock

The factory setting for this shock is at medium stiffness, with the clicker knob (B) set at position 4. The clicker can be actuated with the thumb and forefinger. If bottoming occurs, rotate the clicker clockwise to the next higher number. If full shock travel isn’t being used, rotate the clicker counterclockwise to the next lower number. When adjusting these shocks, we recommend that you turn the clicker only one click at a time, then test ride. Always adjust both shocks equally.

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 the 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. Illustration B indicates high preload and illustration C indicates low preload.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch of preload beyond the factory settings, and ensure that both sides are adjusted the same. When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body.

NOTE: Not all models have shocks with thread adjustable spring

preload. See your dealer for more information.

CAUTION

Always leave one thread showing above the adjuster nut. On models equipped with a plastic adjuster nut, if the nut is unscrewed from the threaded body, the nut will break.

THE PERFECT FIT

Front Suspension Adjustments

Shock Valving

RydeFX or RydeFX SOLO shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired t o control suspension stiffness.

WARNING

Changing shock valving on RydeFX and RydeFX SOLO 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 involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.

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 this 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 In deep snow, a new Hi-fax will offer improved performance over

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. See

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 126.

THE PERFECT FIT

Edge Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the EDGE 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 t he 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 EDGE rear suspension is four inches (X-Y=4).

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

Edge Rear Suspension Adjustments

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.

1-Soft Tension - long end of cam to front 2-Medium tension - short end of cam up 3-Firm tension - long end of cam up

THE PERFECT FIT

Edge Rear Suspension Adjustments

Rear Shocks

Indy Select Rear Shock

Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock.

Locate the adjustment screw (A) near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise t o reduce compression and soften the ride. There are approximately three full turns of adjustment available.

If bottoming continues after the screw has been turned fully clockwise, the torsion spring should be adjusted (see page 37). Return the screw to its original starting position after the torsion spring has been tightened.

THE PERFECT FIT

Edge Rear Suspension Adjustments

Rear Shocks

Polaris Position Sensitive Shock

There are no external adjustments on the Polaris position sensitive (PPS) shock. There is a performance PPS shock kit available for increasing damping, however. If you desire to have the internal valving changed, consult your dealer, or refer to the suspension troubleshooting decal located under the hood or on the clutch guard.

FOX Position Sensitive Clicker Shock

The FOX 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.

Eight positions are labeled on the knob. Position #1 is the softest, or least compression damping. Position #8 is the stiffest, or most compression damping. When adjusting, we recommend that you turn the clicker only one click at a time, then test ride.

THE PERFECT FIT

Edge Rear Suspension Adjustments

Suspension Coupling

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

Front To Rear Coupling and the Front Rear Scissor Stop (FRSS)

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

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

THE PERFECT FIT

Edge Rear Suspension Adjustments

Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS)

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

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

Rear Rear Scissor Stop (RRSS) - Attributes

Moving the RRSS to a higher position, 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

Edge Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the rear rear scissor stop (RRSS). The RRSS is located in the best overall trail riding position when delivered from the factory.

To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position with the scissor stop tool (1) located in your tool kit.

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

A - Stock Position - This setting is most desirable for trail riding.

B - Medium or High Position (standard hole location) - This setting will decrease weight transfer.

C - 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 your optimum ride.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride. Please take the time to read and understand all the possible adjustments available with the M-10 suspension.

Static Sag and Ride Height Settings

Static sag describes the difference in height of the rear bumper from the suspension’s fully extended position to its loaded height, with the rider seated on the snowmobile.

A good initial starting point is four inches of sag, measured at the rear bumper. Too m uch sag will result in bottoming, and too little sag will result in reduced rider comfort.

Sag travel is used to control ride quality and rebound travel. On the M-10 suspension, sag is controlled by two settings, the full range adjuster (FRA) position and the rear spring preload.

5. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown i n the illustration. Record the measurement.

6. Have the rider sit on the snowmobile and bounce up and down on the seat a few times to set in the suspension. While the rider remains seated, measure the distance from the ground to the top of the bumper (dimension Y) and record it.

7. Subtract Y from X and you will have the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). The correct amount of SAG for the M-10 rear suspension is 3-5 inches.

If the measured sag is incorrect, adjust the FRA position and rear spring preload.

Unloaded Loaded

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

FRA Position

The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA:

1. Refer to the initial set-up reference chart (located under the hood of your snowmobile and on page 49) to determine the desired FRA position.

2. To adjust, loosen the hex bolts (A) attaching the rear lower shock cross shaft to the rail beam.

3. Using a 9/16” wrench, loosen the jam nuts (B) on the preload bolts.

4. Adjust the preload bolts (C) to the desired FRA position.

5. Tighten the jam nuts.

NOTE: Make sure the preload bolt contacts the slide block before

tightening the jam nut.

6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).

NOTE: If the M-10 suspension is new, it will take from 25 to 200

miles to properly break in the springs and shocks, at which time the suspension will be softer and may require FRA readjustment.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

Rear Spring Preload

The top section of the crossover tube (the tube at the top of the rear shock) has a threaded collar on it. The rear spring has a lock tab that fits into the collar to allow easy spring preload adjustment. Refer to the initial set-up chart on page 49.

1. To increase preload, use the tool kit spanner wrench to rotate the crossover toward the left side of the snowmobile (clockwise when viewed from below). Rotate toward the right side to decrease preload (counter-clockwise when viewed from below). Be sure the aluminum locknut and adjuster collar are locked against each other before starting the adjustment.

2. While adjusting, keep in mind that spring preload is a fine tuning adjustment. Coarse adjustments should be made using the FR A.

NOTE: Preload is set “softest” when the preload (dimension B in

illustration and set-up chart) is equal to zero. Adjusting spring preload beyond this could cause damage to the threads.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

More M-10 Suspension Ride and Performance Settings

Overload Spring

The overload spring is located inside the main rear spring. Contact is made with this spring only when the crossover tube comes in contact with it toward the end of the travel, which reduces bottoming of the rear suspension. The correct setting of the crossover tube length enables the M-10 suspension to deliver superior performance in “bottoming” situations. This adjustment has no effect on spring pre-load or general ride characteristics of the M-10 rear suspension, it affects only bottoming resistance. To adjust the crossover tube length (dimension C in illustration and set-up chart):

1. Use the spanner wrenches located in the tool kit to unlock the upper lock nut from the adjuster collar.

2. Turn the adjuster collar to the appropriate or desired dimension for the rider’s weight (refer to the initial set-up reference chart located under the hood of your snowmobile and on page 49). Using the spanner wrenches, tighten the upper lock nut firmly against the adjuster collar.

Optional Springs

Optional springs have been designed to allow adaptation of the M-10 suspension to your specific needs. The 140 lbs./in. optional front arm spring would be used when very light load conditions exist, such as operation on very smooth trails, in deep powder or by very light riders. The 300 lbs./in. rear arm spring option would be used when high l oad conditions exist, such as operation by heavy riders on rough trails or very aggressive riding. The available springs for M-10 suspension are listed below.

Location Spring Rate Polaris PN

Front Arm Standard Front Arm Soft Front Arm Firm

160 lbs./in. 140 lbs./in. 180 lbs./in.

7041671-216 7041677-067 7041672-067

Rear Arm Standard Rear Arm Soft Rear Arm Firm

210/278 lbs./in. 135/240 lbs./in.

300 lbs./in.

7041935-216 7042010-216 7042011-067

Overload 1000 lbs./in. 7041936-067

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Other Ride and Performance Settings

Ski Pressure

Your M-10 rear suspension ski pressure is set at t he factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount.

1. To set the limiter, determine if the rider prefers comfort or control. Lean toward the #4 setting for comfort and toward the #3 setting for aggressive riding.

2. For full hole adjustments, remove the 5/16” nut and flat washers from the lower attachments of the limiter straps and relocate the straps to the desired position (i.e. move from position 4 to 3). Replace the nut and washer tighten securely.

3. For half-hole increments (such as 3/4), the limiter straps have slots at the upper pinch bolt. These slots allow the bolts to be loosened (rather than removed) for half-step adjustments. It is now easy to change to half-step hole positions (re-tighten the pinch bolts if loosened).

4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (A) increases ski pressure while the upper hole (B) decreases ski pressure.

NOTE: By design, the BIASED COUPLE design of the M-10

suspension displaces the rear arm as the front arm is compressed. This means that when you raise the front limiter strap, at some point you will collapse the rear suspension arm, which will affect SAG height and reduce rear suspension travel.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Other Ride and Performance Settings

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber.

1. Turn the machine off.

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

3. Place a 10 lb. weight on the track approximately 16” ahead of the rear axle to slightly preload the track.

4. Check for 7/8” - 1-1/8” gap between the wear surface of the metal track clip and the plastic hi-fax (C) . Measure at a point 16” ahead of the rear axle.

If the t rack needs adjustment:

5. Loosen the rear idler shaft bolts (D) and locknuts (A).

6. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track.

7. Tighten the locknuts (A). Then tighten the idler shaft bolts (D) t o 35 ft. lbs. (47 Nm).

NOTE: Always inspect track alignment after track tension

adjustment. Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi-Fax wear will appear on units with track tension set too tight. Refer to the Master Repair Manual for track alignment procedure.

Track

Hi-fax

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Initial M-10 Suspension Set-up Ch art

NOTE: These positions are only preliminary. Experimentation should

follow initial set-up to obtain optimum results. Refer to the suspension troubleshooting decal for additional set-up tips.

INITIAL SET-UP REFERENCE CHART

This chart is a guideline to be used for initial suspension s et-ups.

Your set-up may vary based on your desired riding style.

FRA Position DimensionBDimension

Rider

SOFT FIRM Rear

Crossover

Limiter/Ski

Weight with

full ridin

Spring

Preload

Tube

Leng

Pressure

Settin

fullridin

gear

PreloadLengthSettings

Settings

In / mm In / mm Light / Firm

100 lbs. 1 11/4 005 5/8 143 4/4 3/3

125 lbs. 1 11/2 005 13/16 148 4/4 3/3

150 lbs. 1 11/2 5/16 8 5 13/16 148 4/4 3/3

175 lbs. 11/2 2 5/16 8 5 13/16 148 4/4 3/3

200 lbs. 2 21/2 5/16 8 5 3/4 146 4/4 3/3

225 lbs. 21/2 3 5/16 8 5 5/8 143 4/4 3/3

250 lbs. 3 31/2 5/16 8 5 9/16 141 4/4 3/3

275 lbs. 3 31/2 1/2 13 5 7/16 138 4/4 3/3

300 lbs. 3 31/2 1/2 13 5 3/16 132 4/4 3/3

325 lbs.* 3 31/2 5/8 16 5 3/16 132 4/4 3/3

350 lbs.* 31/2 4 5/8 16 5 3/16 132 4/4 3/3

375 lbs.* 4 5 7/8 22 5 3/16 132 4/4 3/3

*Might prefer optional spring (rear track) Refer to the list on page 46.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

The FAST M -10 ACE (Adjustable Control Electronics) is a new feature available for some FAST M-10 rear suspensions. It enables a rider to easily adjust the suspension for weight and riding style.

The M-10 ACE is an electronically controlled module that replaces the standard M-10 F RA. The ACE changes the rear shock motion ratio by moving the lower shock pivot point a total of 1 1/4 inches, the same amount of adjustment as the standard FRA. A gauge on the console displays the current position of the shock, from soft to firm or somewhere in between.

M-10 ACE Settings

A switch labeled “ESC” on the left-hand control assembly is used to adjust the position of the ACE module. The following instructions describe all the features programmed into the ACE module.

1. By pressing the left hand control switch up (firm) or down (soft) one time, the lower pivot moves .14 inch, giving the operator a total of nine distinct positions. The console gauge will show the current ACE position.

2. If the soft or firm switch is pressed more than one time in succession, it will adjust as many increm ents as the switch is pressed. The electronics will “do the math” for the user to minimize t ravel time. For example, if the rider pushes “firm” twice, and then “soft” three times, the unit will move to one position softer than t he current position.

3. If the soft or firm switch is held for five seconds or more, the ACE will adjust to the far end of the travel, corresponding to which button was pressed.

4. A fail-safe mode has been programmed into the controller to protect the electronics and to notify the operator of a system malfunction. If the module cannot adjust the suspension after one of the switches has been pressed (most likely due to an obstruction or heavy ice buildup), the controller will enter a failure mode, which is indicated by the gauge needle moving rapidly between soft and firm. This mode will continue indefinitely and is reset when the engine is turned off and restarted. If this mode is encountered, we recommend that the operator turn off the engine and inspect the unit for any obstruction or ice buildup on the shock or module.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

M-10 ACE Settings

IMPORTANT NOTES:

The time to move one position can take up to 12 seconds depending on the rear shock loads.

Due t o alternator limitations, the ACE module will operate only at engine speeds above 3500 RP M.

Similar to the FRA on the standard M-10, the ACE module will have the MOST effect on rear suspension performance.

Other M-10 ACE Ride and Performance Settings

Rear Spring Preload

Further fine tuning can be accomplished by adjusting the preload/crossover collar on the rear spring. This single adjustment changes BOTH the spring preload and crossover transition point. Increasing this setting will fine tune the overall ride stiffness AND increase bottoming resistance so a small change to this setting has a large effect on ride quality. To adjust the rear spring:

1. Slide the fabric cover toward the top of the rear spring to reveal the middle spring collars.

2. Using the tool kit spanner wrenches, turn the preload collars to achieve the desired setting as illustrated.

3. Ensure the fabric cover is replaced correctly and is not interfering with shock and spring movement.

NOTE: Refer to the initial set-up chart (on page 52 and under the

hood) for preliminary settings.

Ski Pressure

See the Ski Pressure section for the standard M-10 suspension on page

47.

Track Tension

See the Track Tension section for the standard M-10 suspension on page 48.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

Initial M-10 ACE Set-up Chart

NOTE: These positions are only

preliminary. Experimentation should follow initial set-up to obtain optimum results. Refer to the suspension troubleshooting decal for additional set-up tips.

INITIAL SET-UP REFERENCE CHART

This chart is a guideline to be used

for initial suspension set-up.

Your set-up may vary based on your

desired riding style.

Rider Weight Dimension

imiter/Ski

RiderWeight

with full

Dimension

Preload and

Limiter/Ski

Pressure

riding gear

eoada

Crossover

essue

Settings

In. mm Light Firm

100 lbs. 004/4 3/3

125 lbs. 004/4 3/3

150 lbs. 0.10 3 4/4 3/3

175 lbs. 0.20 5 4/4 3/3

200 lbs. 0.25 6 4/4 3/3

225 lbs. 0.25 6 4/4 3/3

250 lbs. 0.30 8 4/4 3/3

275 lbs. 0.35 9 4/4 3/3

300 lbs. 0.40 10 4/4 3/3

325 lbs.* 0.45 11 4/4 3/3

350 lbs.* 0.50 13 4/4 3/3

375 lbs.* 0.50 13 4/4 3/3

THE PERFECT FIT

Handlebar Adjustment

Standard Handlebars

Follow these steps to adjust the handlebars for a personal fit.

1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts (A).

2. Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).

NOTE: It may be necessary to pry the

adjuster blocks apart with a screw driver.

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

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. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a 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 t o, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use

approved 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 the 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 i s 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.

n 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, increased 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

Traction Products

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

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information.

Some models are manufactured with tunnel wear strips or wear strip coolers installed. 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

Pre-Ride Checklist

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

Item

SeeP

age

Drive Belt Condition 113, 115

Steering System 62

Recoil Rope 62

Coolant Level 101

Park Brake Lock/Brake Lever/Brake System 60, 61, 105

Auxiliary Shut-Off Switch (Engine Stop Switch) 63

Ignition Switch 63

Taillight/Brakelight/Headlight 63

Suspension Mounting Bolts 127

Skags (Wear Bars) 55, 125

Ski Saddle and Spindle Bolts 127

Hood Straps/Latches 62

Seat Latches (if equipped) N/A

Throttle Lever/Safety Switch 59, 74, 75

Rear Wheel Idler Bolts 121, 127

Tether Switch/Strap 63

Track Alignment/Condition 62, 122

Hi-Fax Condition 126

Chaincase Oil Level 92

Injection Oil Level 72

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.

n 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 immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately.

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. See page 105.

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated. See page 74 for procedure.

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 t he 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 108.

Lever Feel

A hydraulic system multiplies the 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 108 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 134 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. To 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 Handle

2. Park Brake Lever Lock (not all models have a park brake)

3. Master Cylinder Reservoir / Cover

4. Fluid Level Indicator

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 of 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 t he steering linkage. Make sure all greasable components are properly lubricated.

n Track In spection

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 t raction 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 .

n Check Hood Latches

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

n Check Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement.

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Transmission: Make sure the reverse is not engaged before

starting your machine.

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

proper operation. Push down to stop the engine. Pull up to release and start the engine.

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

tether from the switch to ensure the engine stops immediately. Make sure the tether strap is in good condition.

n Lighting: 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 clear 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.

n Ignition Switch: Make sure

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

OPERATION

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 59.

Starting a Cold Engine (Manual Start)

Do not depress t he 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 Cold Engine (Electric Start)

Do not depress the throttle until the engine starts.

1. Flip choke toggle to

FULL ON.

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

3. Turn key to START and crank engine.

4. After the engine starts, release the key to ON and flip the choke toggle to OFF. If the engine slows or wants to stop, use intermittent choking to HALF ON.

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 t han 1/4″ open), and pull the rope with your right hand. When the engine starts, immediately release the throttle.

CHOKE TOGGLE POSITIONS

Off

Half On

OPERATION

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

All snowmobile engines equipped with variable exhaust valves should use VES II 2 Cycle Oil (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

Premium

2-Cycle

Premium Gold

2-Cycle

VES II

2-Cycle

Fan Cooled

Good Better N/A

Liquid Cooled

Good Better N/A

Liquid Cooled w/VES

Good Better Best

OPERATION

Track Warm-Up

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.

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 at the rear bumper. The track should be approximately 4″ (10 cm) off the ground.

2. Start the engine and allow it to warm up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several revolutions.

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

Slide Rail and Track Cooling

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.

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 overfill the tank. Do not fill the tank neck. 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 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.

Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible. Always use the premium fuel switch when using premium fuel.

NOTE: Some Polaris snowmobiles require premium gasoline.

Premium Fuel Switch

If 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 keyswitchtoON/PREM. 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 switch to the ON/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.

Premium Fuel Setting

Regular Fuel Setting

OPERATION

Fuel

Fuel Reserve Capacity (Mechanical Gauge)

There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads 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. S ee page 134 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.

OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 67 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 serious engine damage.

Always maintain the oil level above the tank’s low level line. This is especially important when the machine i s operated in mountainous terrain. Maintai ning 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 2-cycle oils for your snowmobile. Never mix brands.

CAUTION

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

n 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.

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

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 carburet or 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 Guidelines

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

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

n 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.

n 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 determinewhat caused the safety switch to activate.

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

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

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

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

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

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 74 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 t ool kit containing essential t ools for emergency use. Machine’ s equipped with electric start have a recoil for emergency starting. On non-electric start models, i f t he 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 and loose clothing 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.

Mechanical Reverse

Make sure the shift lever is shifted completely into forward or reverse position. Some models are equipped with a reverse indicator light that will help you make that determination.

Do not force the shift lever into reverse if resistance is felt. The gears may not always be aligned for shifting into reverse, and forcing the lever may cause damage. If resistance is felt, gently apply the throttle to move the gears to a different position and try to shift again.

The transmission may not always be in the gear indicated by the shift lever. Apply the throttle slowly until you’re sure which gear is engaged.

Sometimes the drive belt will drag in the drive clutch, causing slight tension in the transmission and making it hard to shift. S hutting the engine off will remove this tension and ease shifting. This should only happen during the break-in of a new belt or when the drive/driven clutch center distance is too long. If this is the case, belt tension adjustments should be made by your dealer.

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Electronic reverse will activate only if t he engine is below 4000 RP M. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below. 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 i s clear.

2. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the machine is in reverse.

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 forward

gear when it’s restarted.

Disengaging Reverse

Push the yellow reverse button on the left-hand control 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

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″ (20 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.

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 inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have 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

Polaris Recommended Maintenance Program

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

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

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

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

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

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.

See

Frequency

Item

Page

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Clutch

Clutch Offset Alignment (without belt)

112

I I I

Drive Belt Condition 113 I I I I

Clutches (disassemble) 112 C C C

Belt Tension -- I I I I

Clutch Sheaves 112 I I I I

Engine

Engine Mounts -- I I I I

Recoil Rope -- I I I I

Engine Mounting Plate -- I I I

Engine Torque Stop 116 I I I I

Cylinder Head Bolts -- I I I

Cylinder Base Nuts -- I I I I

Ignition Timing BTDC -- I I I

VES System -- C C C I

Coolant Level 101 I I R I

Water Pump Drive Belt 96 I I I

Coolant Hose -- I I I I

Heat Exchangers 103 I I I I I

Coolant Circulation -- I I I

Coolant Leaks -- I I I I

Spark Plug Condition 94 I I I I I

Exhaust Pipe 100 I I

Exhaust Retaining Springs

100 I I I I

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

MAINTENANCE

Periodic Maintenance Interval Table

See

Frequency

Item

Page

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Brakes

Hose Routing -- I I I I

Hose Condition -- I I I I

Fluid Leaks -- I I I I

Brake Pads 105 I I I I

Brake Disc -- I I I I

Parking Brakes 61 I I I I

Brake System 59, 105 I

Brake fluid 107 R

Fuel Management

Pilot Air Screws -- I I I

Carburetor (synchronize) 73 I I I

Idle RPM -- I I I

Throttle Lever 59, 75 I I I I I

Oil Pump Lever (synchronize)

I I I

Throttle Cable 91 L L L

Choke Cable 91 L L L

Vent Lines -- I I I I

Throttle Position Sensor -- I I I

Choke 91 I I I

Fuel Filter 98 R R

Fuel Lines 98 I I I I I

Oil Filter 98 R R

Oil Lines 98 I I I

Oil Change -- R R

Air Box -- I I I I I

Drain and Water Traps 97 I I I

Electrical

Auxiliary Shut-Off Switch 63 I I I I I

Throttle Safety Switch 59, 74 I I I I I

Ignition Switch -- I I I I I

Taillight 63 I I I I I

Brakelight 63 I I I I I

Headlight 63 I I I I I

MAINTENANCE

Periodic Maintenance Interval Table

See

Frequency

Item

Page

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Chassis

Ski Toe Alignment -- I I I

Suspension Mounting Bolts

I I I I I

Steering Fasteners -- I I I I C

Rear Suspension Fasteners

I I I I I

Suspension Shock Oil -- I I I I

Cooling Fins and Shroud -- I I I I

Drive Shaft Bearings 91 L L L I

Jackshaft Bearings 91 L L L I

Skags (Wear Bars) 55 I I I I I

Ski Saddle/Spindle Bolts -- I I I I I

Ski Pivots 87 L L L L I

Ski Spindle 87 L L L L I

Steering Arm(s) 87 L L L L I

Upper / Lower Steering Post Support Bracket

L L L L I

Drive Chain Tension 104 I I I I I

Hood Straps 62 I I I I I

Battery Fluid Level 131 I I I I I

Rear Wheel Idler Bolts 121 I I I I I

Idler Bolt Jam Nut 121 I I I I I

Rear Suspension Pivot Shafts

L L L

Camber Alignment -- I I I

Radius Rod Bushings -- I

Handlebar Centering -- I

Tether Switch and Strap 63 I I I I I

Track Alignment 122 I I I I I

Track Tension 120 I I I I I

Front Limiter Strap -- I I I I I

Hi-Fax Condition 126 I

Chaincase Oil 92 I I I R I

Gearcase Oil N/A I I I R I

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

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

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

500 Mile (800 km) Maintenan ce Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

1000 Mile (1600 km) Maintenan ce Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

2000 Mile (3200 km) Maintenan ce Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

MAINTENANCE

Maintenance Log

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

MAINTENANCE

Lubrication

Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 134 for the part numbers of Polaris products.

The illustration shows the location of suspension and steering components. A + indicates a grease point or fitting.

S Grease the left and right spindles. Raise the front end of the ma-

chine to permit better grease entry into the spindle area.

S Lubricate both of the front ski pivots at the fittings as shown. S Grease the jackshaft and driveshaft clutch side bearings. S Use an aerosol lubricant on the steering post support bracket. S Grease the center steering arms. S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of unit).

A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 134.

MAINTENANCE

Lubrication

The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. For detailed i nformation about suspension lubrication and adjustments, see your Polaris dealer.

NOTE: The following illustrations are general representations. Your

model may differ. Lubrication points are indicated by a L, and forward is to the left.

MAINTENANCE

Lubrication

MAINTENANCE

Lubrication

Suspension Lubrication - EDGE

Suspension Lubrication - M-10 ACE

MAINTENANCE

Lubrication

Jackshaft Bearing Greasing

Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Push the clutch back onto the shaft and replace the clutch retaining bolt. Torque to 18 ft. lbs. (24.4 Nm).

Driveshaft Bearing Greasing

Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal (approximately two pumps).

Throttle Cable

Lubricate the throttle cable (1) lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.

Choke and Cable

Lubricate the choke slide (2) and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.

MAINTENANCE

Lubrication

Chaincase Oil Level

It’s the operator’s responsibility to check and maintain the proper chaincase oil level.

To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 134 for the part numbers of Polaris products.

Flush the chaincase after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Clean the magnetic plug (B) whenever checking or changing lubricant.

MAINTENANCE

General Maintenance

Spark Plugs

It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.

In selecting a spark plug heat range for production, a manufacturer assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner. This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure. Refer to your Owner’s Manual Supplement for the specific spark plug to be used in your machine.

CAUTION

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

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

S Use recommended spark plugs with the proper gap. Refer to your

Owner’s Manual Supplement for specific information.

S Spark plug torque is 18-22 ft. lbs. (24-30 Nm). S Always carry spare spark plugs in case of an emergency.

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.

MAINTENANCE

General Maintenance

Spark Plugs

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

WARNING

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

NOTE: Incorrect fuel mixture can often cause a spark plug to appear

too dark or too light in color. Before changing spark plug heat ranges, be sure the correct main jet is installed in the carburetor(s). Refer to the Owner’s Manual Supplement or see your dealer.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, t he electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation.

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

5. Install spark plug cap.

MAINTENANCE

General Maintenance

Intake Filter

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

CAUTION

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

NOTE: These illustrations are general representations. Your model

may differ.

1. Intake Foam Filter

2. Air Intake box

MAINTENANCE

General Maintenance

Water Pump Belt Inspection

Some liquid cooled models require inspection of the water pump belt at 1500 miles (2400 km). Inspect belt width (A) and condition, and replace if cracked or worn past the width service limit (.250″ /

6.35mm). New belt width

is approximately .345″ (8.75 mm). See your Polaris dealer if the belt needs to be replaced.

MAINTENANCE

General Maintenance

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 2000 miles (3200 km) and inspected for contamination.

WARNING

When draining the traps, fuel spillage will occur. Always work in a well ventilated area away from anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline warnings found on page 69.

Plug Cleaning Procedure

1. Turn the fuel tank supply valve off.

2. Position a container or shop towels to catch the contaminated gasoline.

3. Slide the clamp (1) away from the drain plug (2) and remove the drain plug from the sediment tube.

4. Wipe residue from the plug and reinstall it. Reposition and tighten the clamps. Continue until all the traps have been emptied.

Polaris Edge Snowmobiles 2004, Edge 2005 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual