Polaris FST Classic, FST Touring, FS Touring, FS Classic User Manual

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WARNING

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

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

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

WARNING

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

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.

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

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) T echnician.

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

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

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

RIDER SELECT is a trademark of Polaris Industries Inc.

Copyright 2005 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.

2006 FS/FST Classic/Touring & FST Switchback Owner’s Manual P/N 9919670

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 27..................................

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

The Perfect Fit 46............................

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

Pre-Ride Inspections 64......................

This section explains procedures that must be performed before riding.

Operation 73.................................

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

Maintenance 85..............................

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

Polaris Products 133.........................

Troubleshooting 134.........................

Warranty 141................................

Maintenance Log 149.........................

Index 152....................................

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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.

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.

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number:

Tunnel VIN (L):

Engine Serial Number (on valve cover):

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 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 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

Follow the recommended maintenance program outlined beginning on page 87 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 or riding as a passenger. They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. Always check major and vital safety components before every ride.

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

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

SAFETY

Operator Safety

Stay Clear of Track

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

WARNING

Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.

WARNING

Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.

SAFETY

Operator Safety

Riding Position

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

WARNING

Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.

Survival Preparation

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

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 SWinter Survival Kit STrail Map SOwner’s Manual SFirst Aid Kit STool Kit

SAFETY

Operator Safety

Riding Apparel

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22.

WARNING

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

Disabled Operators

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

Cargo Overload (Touring)

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

SAFETY

Operator Safety

Rider Capacity

Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation.

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

WARNING

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

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

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

SAFETY

Operator Safety

Excessive Speed

WARNING

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

Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your snowmobile travels. If your speed is 40 MPH, your snowmobile is traveling about 60 feet per second. If you look back for only two seconds, your snowmobile will travel about 120 feet. If your speed is 60 MPH, your snowmobile 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 snowmobile 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 snowmobile will drown out the sound of approaching vehicles. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Avoid travelling on frozen bodies of water.

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. T each them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.

SAFETY

Operator Safety

Avalanches

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

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 avalanche to occur. Be aware t hat all of the snow is connected. You may be riding on a flat slope or snow covered road, but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you. Always be aware of snow conditions above you as you travel in mountainous terrain.

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

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

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

NOTE: If your snowmobile is equipped with RIDER SELECT,

perform this check in both the full up and full down steering positions.

Driving Downhill

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

WARNING

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

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

SAFETY

Operator Safety

Driving on Slippery Surfaces

WARNING

Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution.

Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.

Driving in Hilly Terrain

WARNING

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

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover.

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

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

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

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

Intake Silencer

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

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

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

Maneuverability

While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change for lighter operators or snowmobiles designed to carry a load or a passenger.

SAFETY

Operator Safety

Inadequate Snow Conditions

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

WARNING

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

Operating in Deep Snow

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

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 t o snowmobiling, acquaint yourself with the snowmobile and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile 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.

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

closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.

S Remove the key from the ignition when you leave the snowmobile

unattended.

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Wind

Speed

MPH

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

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

5 36 31 25 19 13 7 1 -5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63 10 34 27 21 15 9 3 -4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72 15 32 25 19 13 6 0 -7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77 20 30 24 17 11 4 -2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81 25 29 23 16 9 3 -4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84 30 28 22 15 8 1 -5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91 45 26 19 12 5 -2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93 50 26 19 12 4 -3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95 55 25 18 11 4 -3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97 60 25 17 10 3 -4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

Frostbitein>> 30 min. 10 min. 5min.

WIND CHILL CHART (°C)

Wind

Speed

KPH

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

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

8 3 0 - -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 16 2 -2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 24 1 -3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 32 0 -4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 40 -1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 48 -1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 56 -2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 64 -2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 88 -3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 96 -3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

Frostbitein>> 30 min. 10 min. 5min.

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

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:

Warming Do not operate with hood open. Do not attempt adjustment with engine running. Do not operate engine with plenum/belt guard

removed. Never run engine with drive belt removed. Never service clutches yourself. See your dealer.

Pressure Cap Warning

This warning decal is found under the hood on the pressure cap of

applicable liquid cooled models:

Warming Do not open hot. Test or replace when changing

coolant. Press down and turn to release cap. 13 PSI

SAFETY

Safety Decals and Locations

“No Passenger” Warning

Snowmobiles designed for a single rider only have a warning decal on the console below the steering post:

Warming This vehicle is designed for

operator only. “NO PASSENGER”

Passenger Warning

Snowmobiles designed for an operator and one passenger have a warning decal at the right side of the steering post. For more information on operating with a passenger, see page 13.

Warming This vehicle is designed for

operator and “ONE” passenger only.

Track Warning

Warming 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.

Safety Decals and Locations

SAFETY

Reverse Warning

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.

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

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

controlto reverse. Flashing light on dash indicates reverse operation.

S Push button again to return to forward.

SAFETY

Safety Decals and Locations

Operation Warning

S To avoid serious injury or death,

read and understand all warnings

and the Owner’s Manual before

operation. If the manual is miss-

ing, contact a Polaris dealer for a

replacement.

S This vehicle is capable of high

speeds. Buried objects or un-

even terrain 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

result 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 vehicle. 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 require-

ments.

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 engine, check throttle, brake, and steering for proper opera-

tion. Make sure hood is latched. Be seated and in position to control the ve-

hicle.

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

FEATURES

1. Front Bumper

2. Hood

3. Headlight

4. Passenger Lumbar Adjuster (Touring)

5. Windshield

6. Handlebar

7. Operator Seat

8. Passenger Seat (Touring)

9. Passenger Grab Handle

10. Grab Handle Heater Switch (Touring)

1 1. Trunk Cover or Storage

Compartment

12. Taillights

13. Rear Bumper

14. Snow Flap

15. Track

16. Suspension

17. Skis

18. Nosepan

FEATURES

1. Fuel Filler Cap

2. Rider Selectt

3. Ignition Switch

4. Handlebar hook

5. Brake Lever

6. MFD (Multi-Function Display)

7. Engine Stop Switch

8. Throttle Control

9. Hood Hold Down Straps

11 12

10. Parking Brake 1 1. Handlebar Grip Warmer

Switch

12. Thumbwarmer Switch

13. Electronic Reverse Button

14. MFD Control

15. Headlight Dimmer Switch

16. Mountain Bar (if equipped)

FEATURES

Passenger Seat (Touring)

The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob (A).

Storage Compartments

Trunk (Touring)

Open the trunk cover (B) to access the rear storage compartment. The passenger seat and trunk cover are removeable to provide open storage for transporting larger items.

1. Remove the trunk cover.

2. Push down on the seat latch lever (C), which is located at the lower rear of the passenger seat.

3. Lift up the seat and remove it from the chassis.

4. Reverse the procedure to reinstall the seat and trunk cover.

Under-Seat Storage (Switchback)

Lift the seat lever (+) and lift the seat to access the under-seat storage area.

Storage Compartment (Classic)

Open or close the storage compartments with the key.

FEATURES

Radiator Compartment Access Panel

The access panel (+) is provided for cleaning debris from the radiator.

Cargo Rack (Switchback)

The maximum weight capacity for the cargo rack (+) is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit. Do not allow a passenger to sit on the seat back or the cargo rack.

Adjustable Headlights

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

FEATURES

RIDER SELECT Adjustable Steering System

The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions.

WARNING

If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability. Removing this lockout and using RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking. This could lead to loss of control resulting in serious injury or death. Always be sure that the handlebars and brake lever do not contact any other snowmobile components at any steering position AND at any RIDER SELECT position.

Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it. Operation in positions 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death.

Choosing the Best RIDER SELECTt Position

Position Riding Style

Relaxed Trail Riding

Rider weight is slightly behind the center of the snowmobile for comfortable and

relaxed riding.

45General Trail Riding, Boondocking,

Deep Snow Riding

Rider weight is centered on the snowmobile, providing balance, comfort and control for both novice and experienced riders. This is the recommended posi-

tion for most riding situations.

67Snowcross/Steep Hill Climbing Only

Rider weight is ahead of the center of the snowmobile, adding weight to the skis and making the snowmobile heavier in the front. These positions are ONLY for snowcross and severe hill climbing.

FEATURES

RIDER SELECT Adjustable Steering System

Adjusting RIDER SELECT

WARNING

Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system.

1. Stop the snowmobile.

2. Press the release button and move the handlebar forward or rearward to the desired position.

WARNING

Do not lubricate the RIDER SELECT mechanism. Doing so could cause loss of control and result in serious injury or death. The RIDER SELECT mechanism is lubricated for life at the factory.

WARNING

Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. Such accessories could limit your ability to steer the vehicle and/or may contact the brake lever. This could lead to loss of control resulting in serious injury or death. Always be sure that accessories do not contact the handlebar or brake lever at any steering position and at any RIDER SELECT position.

FEATURES

Engine Management System

Malfunction Indicator Lamp (MIL)

The MIL (Check Engine Indicator) will illuminate when the ECU detects a problem with engine management system components. If this occurs, see your dealer for service immediately.

The MIL will blink in the event that the ECU detects an error with the turbo boost regulation system. This may be caused by damaged or disconnected hoses between the turbocharger and wastegate solenoid pulse valve (located on the engine side of the airbox) or between the wastegate actuator (located under the turbocharger) and wastegate solenoid pulse valve. If the hose has no damage and is not disconnected, see your dealer immediately.

CAUTION

Serious engine damage may occur if the wastegate reference line is removed or modified. DO NOT remove or modify the wastegate reference line.

FEATURES

Engi

illmisf

Engine Management System

To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (FST) if the following conditions are encountered.

Veh icle Speed is Limited

Cause Function Maximum

Speed

MPH (km/h)

Reverse is selected Reverse 12 (19)

Defective rollover switch Rollover 37 (59)

Throttle stuck, throttle

lever depressed

Throttle safety switch

failure

Maximum vehicle speed Max speed limiter 186 (299)

Throttle stuck, throttle

safety switch high

Throttle safety switch

fault

18 (29)

31 (50)

Engine will misfire

Engine Speed is Limited

Cause Function Maximum

RPM

Reverse is selected,

speed sensor error

Defective rollover switch,

speed sensor error

Throttle stuck, throttle

lever depressed, speed

sensor error

Throttle safety switch

failure, speed sensor error

Throttle stuck, throttle

lever at idle position

Maximum vehicle speed,

speed sensor error

Reverse failure Reverse 2500 ECU cannot de-

Reverse 5300

Rollover 6000

Throttle stuck, throttle

safety switch high

Throttle safety switch

fault

Throttle stuck, throttle

safety switch low

Max speed limiter 8800

5450

6200

2400

reverse or foward

Result

at higher vehicle

speed

Result

ne w

at higher engine

speed

termine whether

is selected

Engine Management System

exceedstablevalue

wit

enginetemperature

exceedstablevalue

wit

enginetemperature

Engine Overheats (FS)

FEATURES

Indication At Vehicle

Speed

MPH (km/h)

Flashing

overheat lamp

Flashing

overheat lamp

engine misfire

0-31 (0-50) 230 (110) Lamp flashes when

32-46 (51-74) 230-221 (110-105)

47-62 (75-100) 221-212 (105-100)

Above 62 (100) 212 (100)

0-31 (0-50) 239 (115) Lamp flashes and

32-46 (51-74) 239-230 (115-110)

47-62 (75-100) 230-221 (110-105)

Above 62 (100) 221 (105)

Engine Overheats (FST)

Indication At Vehicle

Speed

MPH (km/h)

Flashing

overheat lamp

Flashing

overheat lamp

with

engine misfire

0-31 (0-50) 221 (105) Lamp flashes when

32-46 (51-74) 221-212 (105-100)

47-75 (75-120) 212-203 (100-95)

Above 75 (120) 203 (95)

0-31 (0-50) 239 (115) Lamp flashes and

32-46 (51-74) 239-230 (115-110)

47-75 (75-120) 230-221 (110-105)

Above 75 (120) 221 (105)

At Engine

Temp

° F(° C)

At Engine

Temp

° F(° C)

Explanation

engine temperature

engine misfires when

exceeds table values

Explanation

engine temperature

engine misfires when

ine temperature

exceeds table values,

operator mayfee

loss of power

Turbo Boost is Limited (FST)

Indication Result

Illuminated overheat lamp

Engine coolant temperature is at or below 122° F(50° C) OR Engine coolant temperature is at or above 203° F(95° C)

Intake manifold air temperature is at or below 32° F(0° C) OR Intake manifold air temperature is at or above 158° F(70° C)

Overboost condition occurs (CHECK ENGINE MIL lamp will flash)

Fuel octane is too low (use the recommended fuel)

Operator may feel

loss of power

FEATURES

Detonation Elimination Technology (DET) (Turbo Models)

A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance.

NOTE: Engine performance will be reduced if fuel with a lower

octane than 91 is used. See fuel recommendations on page 79.

Effect of DET

The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely. If the system senses detonation beyond a preset limit, it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage.

When the detonation returns to a permissible level, the system will return spark and fuel to normal, allowing the engine to run at rated power levels.

Sensor Fail -Safe

The DET includes a sensor fail-safe system to prevent the engine from damage if the sensor fails, becomes disconnected or is unable to detect detonation. The rider will experience a loss in power. The sensor must be reconnected or repaired to regain full power.

NOTE: The check engine light will illuminate if the sensor fails or

becomes disconnected.

Instrumentation

MFD Component Identification

FEATURES

Item

1 Analog Gauge

2 Digital Gauge

3 Check Engine Indicator

4 High Temp Indicator

5 Brake Indicator

6 Reverse Indicator

7 High Beam Indicator

Digital Display Identification

Item

1 RPM or Speed

Altitude (if equipped) Service Interval

2 Electrical System Voltage

Level

3 MAX - Ma x imum MPH/

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

revolutions per minute

4 Air Temp (if equipped)

Engine Temp Degrees Celsius Degrees Fahrenheit

5 Miles

Kilometers

6 Hours

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

7 Fuel Level (FS) or Turbo

Boost (FST)

FEATURES

Instrumentation

MFD Settings

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

Use the MFD Control Switch (A) to set the MFD display to your preference. The rocker switch has a MODE button (B) and a SET button (C).

Standard vs. Metric

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

Speedometer/Tachometer

The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).

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

Option Analog

Display

1 Speed RPM Blue “mph” Blue

2 RPM Speed Red “X100rpm” Red

Digital

Display

Analog Screen

Digital

Screen

Backlight

FEATURES

Instrumentation

MFD Digital Display Programs

Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected.

NOTE: The analog will always display either MPH or engine RPM

Performance Program

The Performance Program automatically displays either speed or tachometer, whichever is opposite the analog display. See page 38. It also displays electrical system voltage and fuel levels.

While in the Performance mode, press the SET button to cycle through the odometer, Trip 1, Trip 2, Trip F and Clock settings.

Trip Settings

Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled.

1. To reset a trip odometer to zero,

2. Press and hold the SET button for

Trip F automatically displays if the fuel level is low. The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank. The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1/4 tank. The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1/4 tank. The Trip F odometer will automatically reset to zero after refueling.

(whichever setting is selected) regardless of the display program being viewed.

entertheTrip1orTrip2display.

two seconds.

Odometer Setting

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

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Clock Setting

1. While in the CLOCK display, press and hold the SET button for five seconds.

2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the hour once every 0.2 seconds.

3. Press the MODE button to save the hour and flash the minutes.

4. Set the minutes in the same manner.

5. When finished, press the MODE button to save t he new setting.

NOTE: If the MODE button is not pressed within ten seconds, the

Engine Program

The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level. On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air temperature will display as additional screens in the engine program. Press the SET button to display the ambient air temperature and altitude screens (if equipped). On turbo-charged models, the boost pressure screen follows these two screens.

Air Temperature (if equipped)

The MFD displays actual air temperature. Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.

clock will automatically save the new entry.

FEATURES

Instrumentation

MFD Digital Display Programs

Altitude (if equipped)

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

NOTE: Press and hold the MODE switch

for ten seconds to switch between standard and metric units of measurement. When “ALt” displays, the program is in the metric mode.

1. Enter the Engine Program and select the altimeter display.

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

3. When the digits begin to flash, press the SET button once to advance 50 feet (15 m), or press and hold the button to advance 100 ft. (30 m) every 0.1 seconds. Adjust the altitude display to within 50 ft. (15 m) of current altitude.

NOTE: The gauge reads barometric pressure and allows the rider to

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

4. Press the MODE button to hold the reading at the adjusted value. If it’s not pressed within five seconds, the gauge will automatically save the new setting.

Hour Meter

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

Engine Temperature

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

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

The History Program automatically displays electrical system voltage level and fuel level.

While in the History mode, press the SET button to view maximum vehicle speed, m aximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed.

The History Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings.

Maximum Speed/RPM Reset

While in either the MAX MPH or the MAX RPM mode, press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM. Both of these values are reset at the same time. Reset the MAX MPH/RPM values before each run to obtain accurate readings.

NOTE: Due to electrical noise, the

MFD may occasionally display MAX MPH/RPM values that are not representative of actual values.

FEATURES

Instrumentation

MFD Digital Display Programs

Service Interval Reminder

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

See the maintenance charts beginning on page 88 for recommended service intervals.

To reset the reminder at the existing interval:

1. Enter the service interval screen.

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

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

To reset the reminder at a new interval:

1. Enter the service interval screen.

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

3. Immediately release the button.

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

NOTE: The maximum interval is 250 hours.

To disable the service interval reminder, press the SET button once after reaching 250 hours on the display. The gauge will display “OFF”.

FEATURES

Instrumentation

MFD Battery Replacement

If the clock function of the MFD isn’t working properly, replace the battery. Replacement batteries are available from your dealer.

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

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

3. Cut the plastic cable tie (B) from the outside of the compartment.

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

NOTE: Note the orientation of the battery before removing it. An

incorrectly installed battery will not maintain the clock.

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

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

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

FEATURES

Instrumentation

MFD Battery Replacement

6. Install a new battery with fingers only.

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

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

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

Gauge Cleaning

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

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

CAUTION

To prevent damage to the lens, do not use alcohol for cleaning. Do not allow chemicals or sprays to come into contact with the lens. Immediately clean off any gasoline that splashes on the gauge during refueling.

THE PERFECT FIT

IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments.

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

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

S Shock damping (if equipped

with ArvinMeritor MPV Select shocks)

S Front shock spring preload S Optional springs S Optional shock valving

(Switchback)

S Toe (ski alignment) (see page 126) S Camber (see your dealer)

THE PERFECT FIT

IQ Front Suspension Adjustments

Shock Damping

Adjustments to the compression stiffness of ArvinMeritor M PV Select shocks can be made by turning the adjustment screw (+) located near the base of the shock. This adjustment is the easiest to perform and it should be considered first.

The factory setting for this shock is the softest position, with the adjusting screw all the way out (counterclockwise). If bottoming occurs, turn the screw clockwise to increase compression and stiffen 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.

Front Shock Spring Preload

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

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

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

THE PERFECT FIT

IQ Front Suspension Adjustments

Shock Valving (Switchback)

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

WARNING

Changing shock valving 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

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 t he trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.

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

Suspension Performance Tips

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

load should be set. However, t his 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 rail slide will offer improved performance over

a worn slide. It can also improve top speed.

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 98.

THE PERFECT FIT

Switchback Rear Suspension

Initial Spring Preload Setting (Sag Method)

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

Take this 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 suspension.

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

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. See illustration. The ideal amount of sag for this rear suspension is five inches (12.7 cm) (X-Y=5 in./12.7 cm).

If the rear suspension rides in less than four inches or more than six 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 setup, and final spring preload may vary based on rider preference and riding conditions.

THE PERFECT FIT

Switchback Rear Suspension

Rear Torsion Spring Tension

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

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

A. Soft Tension - long end of cam to front B. Medium tension - short end of cam up C. Firm tension - long end of cam up

Limiter Strap Position

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

A. Limiter strap in high position

increases ski pressure

B. Limiter strap in low position

decreases ski pressure

THE PERFECT FIT

Switchback Rear Suspension

Rear Track Shock Compression Damping

A. Turn rear track shock screw clockwise to stiffen compression. B. Turn the rear track shock knob clockwise for a softer ride. C. Turn the rear track shock knob counter clockwise for a stiffer ride.

THE PERFECT FIT

Switchback Rear Suspension

Rear Shocks

When adjusting, we recommend that you turn the adjuster slightly, then test ride. The recommended setting for this shock is eight (8) clicks counter-clockwise.

FOX Zero Pro XC Shock

The FOX Zero Pro XC shock is standard on the Switchback model. Turn the adjustment knob (L) on the shock reservoir to make adjustments to the compression damping.

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. (11 kg) 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 this 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. Too much sag will result in bottoming, and too little sag will result in reduced rider comfort.

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

1. 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 in the illustration. Record the measurement.

2. 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.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

3. 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 FAST M-10 rear suspension is 3-4 i nches (8-10 cm).

If the measured sag is incorrect, adjust the FRA position and rear spring preload. See pages 56--57.

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 or on page 59) 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: When the M-10 suspension is new, it will take from 25 to 200

miles (40-300 km)to properly break in the springs and shocks, at which time the suspension will be softer and may require FRA re-adjustment.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

Rear Spring Preload

If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag. See your Polaris dealer for assistance.

OPTIONAL RETAINERS

Retainer Insert

Part Number

5436109

Retainer Part

Number

5135077

(standard on

M10-128)

5134923 Middle Middle

5135080

(standard on

M10-136)

Preload Sag

Least Most

Most Least

NOTE: Whenever ordering any of the retainers listed in the chart,

always order the retainer insert as well. The insert is not removeable once installed, so a new insert is needed when installing a new retainer.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

Ski Pressure

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

1. 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. Re--tighten the pinch bolts.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

Ski Pressure

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.

Initial M -10 Suspension Set-up Charts

These charts are a guideline to be used for initial suspension set-ups. Your set-up may vary based on your desired riding style.

M10-128

Rider Weight

with Gear

(lbs.)

Under 100 1to11/2

100-150 1 1/2 to 2

150-200 2to21/2

200-250 2 1/2 to 3

250-300 3to31/2

300-350* 3 1/2 to 4

350+* 4to5

*You may prefer an optional rear track middle spring retainer. See page 57.

Suggested FRA

Range (Lower

Number is Softer)

Rider(s)

Weight with

Gear (lbs.)

Under 100* 1to11/2

100-150* 1 1/2 to 2

150-200* 2to21/2

200-250 2 1/2 to 3

250-300 3to31/2

300-350 3 1/2 to 4

350+ 4to5

M10-136

Suggested FRA

Range (Lower

Number is Softer)

THE PERFECT FIT

Handlebar Adjustments

Use the RIDER SELECT feature to adjust handlebar position. See page 31. Use the following steps to adjust handlebar angle at the handlebar block.

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

NOTE: If equipped, remove the

mountain bar (C).

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

NOTE: If necessary, pry the

blocks apart with a screwdriver.

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. (15-18 Nm).

NOTE: Torque the front bolts first.

5. Reinstall the handlebar cover.

THE PERFECT FIT

Passenger Grab Handle Adjustment (Touring)

On some Touring models the position of the passenger grab handles can be adjusted for rider preference. To make an adjustment:

1. Unscrew and remove the knob assemblies (A) that secure the grab handles.

2. Reposition the grab handles to one of the three available positions on the grab handle tube between the operator seat and the passenger seat.

3. Reinstall the knob assemblies and tighten securely .

Accessories

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

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

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

This applies, 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

Traction Products

Studs

Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products.

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.

See your dealer about installing studs and/or carbides.

CAUTION

Always install wear strips before installing studs. Failure to install wear strips may result in cooler or tunnel damage. See page 63.

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.

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.

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.

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 the outside edge of the track.

THE PERFECT FIT

Traction Products

Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page

127.

If your snowmobile has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer’s track studding chart.

Wear Strips

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

Install the appropriate wear strip kit. See your dealer.

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

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

SeeP

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

Drive Belt Condition 117, 117

Steering System 66

Park Brake Lock/Brake Lever/Brake System 67, 68, 111

Throttle Lever 65, 81

Throttle Safety Switch 65, 80, 83

Auxiliary Shut-Off Switch (Engine Stop Switch) 71, 83

Ignition Switch 71, 83

Taillight/Brakelight/Headlight 71

Coolant Level 106

Gearcase Oil Level 100

Engine Oil Level 92

Foam Oil Breather Element 97

Suspension Mounting Bolts 70

Skags (Wear Bars) 63, 127

Ski Saddle and Spindle Bolts 70

Hood Straps/Latches 66

Seat Latches 65

Rear Wheel Idler Bolts 123, 70

Track Alignment/Condition 69, 124

Rail Slide Condition 124

Oil Level (check before operating if vehicle was tipped over) 72

age

PRE-RIDE INSPECTIONS

Check Before Starting the Engine

WARNING

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

Read and Understand Your Owner’s Manual

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

n T h rottle Lever

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

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

n T h rottle Safety Switch

Test the throttle safety switch system before the snowmobile is operated. See page 80 for procedure.

n Seat Latches

Ensure that the seat latches are securely in place before every use of the snowmobile.

PRE-RIDE INSPECTIONS

Check Before Starting the Engine

Hood Latches

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

n Steering System

WARNING

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

NOTE: If your snowmobile is equipped with RIDER SELECT,

perform this check in both the full up and full down steering positions.

PRE-RIDE INSPECTIONS

Check Before Starting the Engine

Brakes

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

Brake Lever Travel

Squeeze the brake lever . It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 113.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 112.

Check for the presence of air in the fluid system. See page 113 for more information, or see your dealer for service.

1/2″ (1.3 cm)

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

Check Before Starting the Engine

Park Brake L ever Lock

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

A. Brake Lever B. Park Brake Lever Lock C. Master Cylinder

Reservoir / Cover

D. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forwardonthelock. Holdthe lock forward while releasing the brake lever.

NOTE: If the brake lever is squeezed tightly enough, the lock will

The park brake light on the gauge, will light up if the park brake lever lock is set while 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.

Lock Release

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

move freely into place. Do not force the lock or it may break.

WARNING

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

PRE-RIDE INSPECTIONS

Check Before Starting the Engine

Track Inspection

WARNING

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

Use of traction products such as studs increases the possibility of track damage and/or failure. Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods, break track edges and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions.

NOTE: Track damage or failure caused by operation on ice or poor

lubrication conditions voids the track warranty.

PRE-RIDE INSPECTIONS

Check Before Starting the Engine

Suspension Inspection

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

Item Check Page

Suspension mounting bolts Tightness --

Rear idler wheel bolts Tightness 123

Rear idler adjusting bolt locknuts Tightness --

Torque arm bolts Tightness --

Carrier and bogie wheel bolts Tightness --

Front torque arm limiter strap Condition --

Rail slide Condition 124

Track Tension 122

All rear suspension components Lubrication 98

Ski runner/skag Condition --

Ski s pindle bolts Tightness --

Tie rod end nuts Tightness --

PRE-RIDE INSPECTIONS

Check After Starting the Engine

n Engine Stop Switch

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

n Ignition Switch

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

n Lighting Check the headlight (high and low beam), taillight, and brake light.

Replace burned out lamps before operating.

n Mirror Adjustment

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

n Operating Area

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

PRE-RIDE INSPECTIONS

n Tip-Over Inspections

In the event of a tip-over or rollover, check the oil level before operating the snowmobile.

CAUTION

Failure to check the oil after a tip-over can result in serious engine damage. Always check the oil level before operating a snowmobile that has tipped over or rolled over.

NOTE: In the event of a tip-over or rollover, the engine will stop. To

restart the engine, turn the key to the OFF position, then restart.

WARNING

Operating a snowmobile with accident damage can result in serious injury or death. Do not operate the snowmobile if vehicle components have been damaged in a collision or tip-over. Have the snowmobile inspected by an authorized Polaris dealer.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. 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.

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

Break-In Period

The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Excessive heat build-up during the first 500 miles (800 km) of operation will damage close-fitting engine parts. Do not operate at full throttle or high speeds for extended periods during the break-in period.

Use of non-recommended oil may cause serious engine damage. Always use the recommended oil for your Polaris snowmobile.

1. Fill the fuel tank with the recommended fuel. See page 79.

2. Check the oil level in the oil tank. See page 92. Add oil if necessary to maintain at the recommended level.

3. Drive slowly at first. Vary the throttle positions. Do not operate at sustained idle.

4. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 64.

5. During the break-in period, change both the oil and the filter at 500 miles or before seasonal storage, whichever comes first.

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 65.

Do not depress the throttle until the engine starts.

1. Turn the key to the ON position.

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

CAUTION

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

3. Turn the key to START to crank the engine. Release the key to the ON position when the engine starts.

4. Repeat the cranking procedure as needed until the engine starts.

OPERATION

Emergency Starting

If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions below.

WARNING

Improperly connecting or disconnecting jumper cables can result in an explosion and cause serious injury or death. When connecting jumper cables, always connect the negative (usually black) cable last. When removing jumper cables, always disconnect the negative (usually black) cable first.

WARNING

Loose-fitting clothing can get caught in the engine when the vehicle is running with the hood open. This can cause serious injury or death. Remove or control all items that could catch in the engine, including scarves, gloves, jackets and clothing straps and hooks.

NOTE: If a car or truck battery will be used to jump start the

NOTE: Never attempt to jump start a discharged battery that is

1. Always wear eye protection when jump starting your vehicle.

2. Keep bystanders away from the vehicles.

3. Perform the emergency starting procedure in a well-ventilated area.

4. Position the vehicles close enough for the jumper cables to reach

5. Lock the parking brakes on both vehicles to prevent accidental

6. Open the hood and remove the left side panel.

7. Decide which of the jumper cables will be positive (usually red or

NOTE: Never connect a jumper cable to the fuel system or fuel lines.

snowmobile, turn the engine off. A running engine will put out too much electrical current for the snowmobile battery.

frozen.

easily between the batteries, but do not allow the vehicles to touch each other.

movement.

yellow) and which will be negative (usually black).

OPERATION

Emergency Starting

8. Pull back the red plastic boot covering the positive terminal of the weak battery. Connect one end of the positive jumper cable to the positive terminal of the weak battery.

9. Connect the other end of the positive jumper cable to the positive terminal of the charged battery.

NOTE: Make sure that the end of the negative cable by the weak

battery is not contacting the snowmobile battery or chassis.

10. Connect the other negative end of the jumper cable to the negative terminal of the charged battery.

11. Connect the end of the negative jumper cable by the weak battery to the CHASSIS of the snowmobile. There may be a small spark when this is done, but this is normal.

NOTE: Always be sure that the jumper cables do not interfere with

the belts, pulleys or clutches on either vehicle.

12. Make sure that the engine stop switch is in the UP position.

13. Attempt to start the vehicle.

14. If the engine does not turn over (crank over), wait 30 to 60 seconds and attempt to start the engine again. If the engine does not start, wait another 1 to 2 minutes and attempt to start the engine again.

15. If the engine still does not start, try adjusting the clips on the jumper cable ends to ensure that they have a good electrical connections. Repeat step 14.

16. If the engine still does not start, remove the jumper cables as outlined in step 17 and transport the snowmobile to an authorized Polaris dealer for service.

17. Carefully remove the jumper cables in this order:

A. Remove the negative end of the jumper cable from the

snowmobile chassis.

B. Remove the negative end of the jumper cable from the

charged battery.

C. Remove the positive end of the jumper cable from the

charged battery.

D. Remove the positive end of the jumper cable from the weak

battery.

18. Reinstall the left side panel.

19. Close and secure the hood.

OPERATION

Track Warm-Up

WARNING

A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. 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 rear of the snowmobile at the rear bumper. The track should be approximately 4″ (10 cm) off the ground.

2. Start the engine and allow it

to warm up two to three minutes.

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

revolutions.

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 snowmobile to the ground.

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

to loosen snow and ice.

OPERATION

Fuel

For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane.

CAUTION

Operating with obstructed fuel systems will result in serious engine damage. Perform maintenance as recommended.

Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank. Do not allow the snowmobile to run out of fuel. Always refuel when the level is low.

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

Fuel Level

The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank. There will be approximately one gallon of fuel remaining. Refuel as soon as possible. Do not allow

the snowmobile to run out of fuel.

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 133 for the part numbers of Polaris products.

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

OPERATION

n Engine Stop Switch

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

n Throttle Safety Switch

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

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 throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

Test the throttle safety switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it to

idle.

3. Hold the throttle lever pin

stationary by exerting pressure on the pivot pin in the direction shown in the illustration (L).

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

OPERATION

n Throttle Lever

WARNING

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate.

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

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

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

NOTE: Excessive freeplay in the throttle cable may cause the safety

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

switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized Polaris dealer for service.

Turbo Noise (FST )

Under some conditions, when the throttle lever is released the boost pressure dump valve will release pressure, and you may hear the sound of escaping air. This is a normal occurrence on turbo-charged models.

OPERATION

Electronic Reverse (PERC 4t)

Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum engine speed when operating in reverse will be 6000 RPM.

WARNING

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed.

S Shift to or from reverse only when the snowmobile is stopped

and when engine speed is at idle.

S Look behind the snowmobile before and while backing. S Avoid sharp turns. S Apply throttle slowly .

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your snowmobile is clear.

3. Push the yellow reverse button on the left-hand control for one second, then release.

NOTE: A reverse light on the instrument panel will indicate that the

snowmobile is in reverse.

4. Apply the throttle slowly to make sure the snowmobile is in reverse.

NOTE: If the engine stops running, the snowmobile will be in forward

gear when it’s restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut off.

3. Apply the throttle slowly to make sure the snowmobile is in forward.

OPERATION

n Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 80 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

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

OPERATION

Daily Storage

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

Remove the key and cover the snowmobile.

Towing

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 t ow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have someone ride on the towed snowmobile to operate the brake and steering when necessary.

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

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. The emission control system designation per SAE J1930 is MFI. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. S pecifications and adjustments for engine tune-ups are located in the Service Manual, which i s available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

MAINTENANCE

Emission Control Information

Owner’s Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty on page 147, and read the maintenance section of your owner’s manual. You are responsible for ensuring that the specified maintenance is performed, including the emission--related maintenance outlined in these sections of the manual.

You must inspect the air intake system on your snowmobile prior to each use (including the airbox foam filter and hood foam filters) and clean these components as necessary. Polaris considers the specified maintenance for the spark plugs, oil changes, air intake system and exhaust valves to be critical emission--related maintenance. The specified maintenance for the fuel filter is recommended additional emission--related maintenance. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 149.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1500 miles (2400 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1500 mile (2400 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.

NOTE: Polaris does not recommend tipping the snowmobile onto it’s

side for service. Any time the snowmobile is tipped onto it’s left side, always check the oil level and clean the foam oil breather element. See page 97.

CAUTION

Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

Tool Kit

A tool kit is included with each snowmobile for emergency use. Always keep the tool kit with the snowmobile.

MAINTENANCE

ppp

dealerforservic

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Periodic Maintenance Interval Table

D = Perform Service

" = Replace

Item Pg Instructions

(see referenced pages)

Engine Stop Switch

Ignition Switch

Throttle Safety Switch

Taillight

Brakelight

Headlight

Skags (Wear Bars) 127 Inspect for wear or damage, replace

Fluid Leaks

Parking Brake 68 Test for proper engagement and re-

Brake Lever

Coolant

Brake fluid

Hood Latches

Seat Latches

Rail Slide 124 Inspect for wear or damage, replace

Foam Oil Breather Element

Front/Rear Suspension and Steering Fasteners

Front Limiter Strap

Oil Lines

Alternator Belt 104 Check tension and condition,

Test for proper operation. Do not operate ifswitchesfail, see your

dealer

or service.

Test for proper operation, replace bulbs as needed

when worn

-- Inspect for fluid leaks

lease, see your dealer for service

67 Check lever travel and lever “feel”

106

Inspect level, add as needed

112 Inspect fluid level, add as needed

Secure properly, replace if damaged

when worn

97 Check pre-ride, clean or replace

with each oil change. Clean after tipping 3 times onto left side.

70 Inspect for missing or loose bolts

and fasteners, tighten or replace as needed

-- Inspect for wear, damage and missing or loose fasteners, replace as needed

-- Inspect, replace if worn or damaged

replace if worn or damaged

DAILY

INITIALLY

or PRERIDE

D CHANGE EVERY 2 YEARS

D D D D

(km)

150

500

(240)

(800)

WEEKLY / BEFORE LONG TRIPS

D D D

YEARLY

or EVERY

(km)

1500

(2400)

MAINTENANCE

Periodic Maintenance Interval Table

D =Perform

" = Replace

Item Pg Instructions

(see referenced pages)

Coolant Hoses

Heat Exchangers

Throttle Lever 65

Fuel Lines

Battery

Track Alignment

Track Tension

Handlebars

Drive Chain

Rear Track Shock (M-10)

Gearcase Oil 100 Check at 500 mi. (800 km), change

Rear Suspension 98 Lubricate pivot shafts

Bearings 131 Lubricate drive shaft and jackshaft

Throttle Cable

Clutches 11 6 Verify offset alignment, inspect for

Drive Belt 117 Check tension and condition,

Air Filter 104 Inspect for oil and dirt, replace as

Oil/Filter Change

Inspect, replace if worn or damaged

Inspect, replace if damaged

103 Inspect, replace if worn or damaged

Clean terminals, test voltage

124

Verify alignment, adjust as needed

122

Verify tension, adjust as needed

Verify alignment, adjust as needed

110

Verify tension, adjust as needed

-- Inspect covers and caps for wear or damage, replace as needed

every 1000 mi. (1600 km)

(more often in wet snow conditions)

bearings

Lubricate

wear, residue, loose bushings, see your dealer for all service

replace if worn or damaged

needed

Replace oil and filter

DAILY

or PRERIDE

INITIALLY

(km)

150

500

(240)

(800)

D D D

EVERY

D D

" "

YEARLY

or EVERY

(km)

1500

(2400)

EVERY

1000 (1600)

MAINTENANCE

Periodic Maintenance Interval Table

D =Perform

" = Replace

Item Pg Instructions

(see referenced pages)

Engine Mounts

Spark Plugs 102 Inspect condition/gap, replace as

Exhaust System 105 Check muffler and pipe condition,

Hoses -- Inspect for wear, damage and prop-

Brake Pads/Disc

Fuel Vent Lines

Ski Toe 126 Verify alignment, see your dealer for

Cooling Fins/ Shroud

Valve Lash -- See your dealer.

Cooling System 107 Bleed the cooling system, inspect

Fuel Filter

Suspension Shock Oil

Inspect, replace if worn or damaged

needed

replace damaged or missing components, clean plastic surfaces

er routing, replace as needed

111 Inspect, replace if worn or damaged

103

Inspect, replace if worn or damaged

adjustments

-- Inspect and clean

Specifications

Intake: 0.08 - 0.15 mm Exhaust: 0.15 - 0.20 mm

FST

Specifications

Intake: 0.08 - 0.15 mm Exhaust: 0.18 - 0.23 mm

for leaks and proper circulation

103

Inspect, replace as needed

Classic/Switchback only, see your dealer for inspection

DAILY

or PRERIDE

INITIALLY

(km)

150

(240)

500

(800)

D D

D EVERY

YEARLY

or EVERY

(km)

1500

(2400)

3000 (4800)

EVERY

2000 (3200

EVERY

2000 (3200)

EVERY

2000 (3200)

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance T able beginning on page 88. Always change the oil filter whenever changing oil. See page 133 for the part numbers of Polaris products.

Performance Synthetic 4-Stroke (PS-4) Oil

Polaris recommends the use of Performance Synthetic 4-Stroke (PS-4) 0W50 oil for this engine. PS-4 has been specially formulated for use in Polaris 4-cycle snowmobile engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Oil may need to be changed more frequently if Polaris oil is not used. Always use 0W50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

MAINTENANCE

Engine Oil

Oil Level Check

NOTE: Read the entire oil check procedure before checking the oil

level.

The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. To obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant temperature must be between 145 and 160 degrees F. (63-71 degrees C). Never add or remove oil if the engine coolant temperature

is not within the specified range.

NOTE: Always check the oil level before operating a snowmobile

that has tipped over.

CAUTION

Severe engine damage may occur if procedures for checking the oil level are not followed precisely. Always check the oil with the snowmobile positioned on a level surface. Always check the oil when the coolant temperature is within the specified range.

1. Position the vehicle on a level surface.

2. If the engine is cold, start the engine and allow it to idle until the engine coolant temperature reaches the specified range. Proceed to step 4.

3. If the engine has been running, stop the engine and verify that coolant temperature is within the specified range for performing the oil check. Allow the engine to cool if necessary. When the coolant is within the specified range, restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank.

4. Turn the engine off.

NOTE: Check the oil level within

three minutes, before the coolant temperature (and oil level) begin to drop.

5. Remove the dipstick (L) from the oil tank.

MAINTENANCE

Engine Oil

Oil Level Check

6. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely.

7. Remove the dipstick and view the oil level.

NOTE: The oil level reading will be accurate for only one to three

minutes after turning off the engine. If the oil check isn’t completed within three minutes, reinstall the dipstick. Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank.

A. Fill mark for oil changes (at specified coolant temperature) B. Safe operating range

8. Maintain the oil level in the safe operating range (B), between the upper and lower marks on the dipstick. If the level is low, add the recommended oil in small increments, about 2 ounces (60 ml), and recheck the level. If the level is high, remove 2 ounces (60 ml) and recheck the level.

CAUTION

Do not overfill the oil tank. Engine damage may occur. Always add oil in small increments and recheck the level to avoid overfilling.

9. Recheck the oil level if oil was added or removed, making sure the coolant temperature is within the specified range. If necessary, continue adding or removing oil until the level is in the safe operating range.

MAINTENANCE

Engine Oil

Oil Change

Always change the oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Clean the foam oil breather element with each engine oil change. See page 97.

Always use the recommended oil. See page 91, or see your Polaris dealer about oil change kits, which contain a new filter and the recommended oil.

NOTE: A special jumper harness is required for changing the oil on

1. Position the vehicle on a level surface.

2. Make sure the engine coolant temperature is between 145 and 160

3. Turn the engine off.

this vehicle. Please see your Polaris dealer to purchase the harness, which will allow you to use the ignition key to turn over the engine without starting it. You may also need an assistant to help with the oil change.

degrees F. (63-71 degrees C). If necessary, start the engine and allow it to idle until the coolant temperature is within the specified range.

CAUTION

Hot oil and a hot exhaust system and engine can cause serious burns. Do not allow hot oil or hot components to contact skin.

4. Open the hood and remove the left side panel.

NOTE: Clamp orientation is critical to the proper operation of the

system. Be aware of clamp placement and orientation when removing hose clamps. Always reinstall hose clamps in the same location and position.

5. Remove the oil return hose from the oil tank. Have an assistant place the end of the hose into a drain pan.

6. Disconnect the starter motor solenoid control switch harness.

7. Insert the female WHITE/RED plug into the male pin from the starter motor solenoid.

8. Insert the BROWN male pin of the jumper harness into the starter solenoid’s female port.

MAINTENANCE

Engine Oil

Oil Change

9. Open the handlebar cover. Locate the connector with the BROWN and RED/WHITE wires. Connect the BROWN wire from the jumper harness to the BROWN wire on the handlebar harness by inserting the harness plug i nto the handlebar wiring harness connector.

10. Open the fuse box and remove the 20A EFI fuse from the fuse block.

11. Reinstall the left side panel.

12. Have an assistant use the i gnition key to turn over the engine. Crank the engine for 15 seconds.

13. Wait 30 seconds to allow the starter motor to cool down.

14. Repeat steps 12 and 13 four more times for a total of five cycles.

15. Reconnect the oil return line to the oil tank. Tighten the hose clamp securely, but do not over-tighten.

16. To prevent oil spillage, wait 3 to 5 minutes to allow any oil in the oil filter cap to drain out before removing it. While waiting, remove the foam oil breather element from the airbox. See page

97.

17. Inspect the foam element. Clean it with soap and water and let it dry. Reinstall it, or install a new element if the existing element is damaged or degraded and unable to absorb liquid.

18. Remove the oil filter cap, then remove the oil filter. Inspect the o-ring and replace it if it’ s worn or damaged.

19. Install a new filter, then reinstall the cap. Tighten the cap to 17 ft. lbs. (23 Nm).

20. Remove the jumper from the starter motor wiring harness. Reconnect the solenoid and the originally-installed harness. Reinstall the 20A EFI Fuse.

21. Remove the dipstick from the oil tank. Add 2 quarts (1.9 liters) of the recommended oil. Reinstall the dipstick.

MAINTENANCE

Engine Oil

Oil Change

22. Make sure the engine coolant t emperature is between 145 and 160 degrees F. (63-71 degrees C). If necessary, start the engine and allow it to idle until the coolant temperature is within the specified range.

23. Remove the dipstick from the oil tank. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely.

24. Remove the dipstick and view the oil level.

A. Fill mark for oil changes (at specified coolant temperature) B. Safe operating range

25. Add additional oil to bring the level to the oil change fill mark (A). See the chart for approximate amounts to add at this step. DO NOT OVERFILL.

MODEL OIL TO ADD AT STEP 25

Ounces Milliliters

FS 4to16 118to473

FST 24 to 32 710 to 946

NOTE: Check the oil level often during the fill procedure to avoid

overfilling. If the filling and checking procedure is not completed within three minutes, reinstall the dipstick. Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank. Continue adding and checking the oil until the level reaches the oil change fill mark. Do not overfill.

26. Reinstall the dipstick.

MAINTENANCE

Foam Oil Breather Element

The foam oil breather element absorbs small amounts of liquid to protect sensors within the intake system from damage due to oil ingestion. Clean or replace the breather element at each engine oil change. Clean the element if the snowmobile has been tipped on its left side three times, either during service or while riding, as oil may leak into the element.

CAUTION

Operating the snowmobile with a clogged foam oil breather element can result in severe engine damage. Always clean or replace the element as recommended.

The foam oil breather element is located inside the airbox.

A. FS foam element B. FST foam element

1. Open the hood.

2. Release the airbox cover retaining clips and remove the cover.

3. Remove the foam breather element.

4. Wash the foam element in soapy water, then rinse thoroughly and let dry.

NOTE: If soap and water are not

readily available, remove as much liquid as possible by pressing the foam element in paper towels or a similar absorbent material.

5. Reinstall the dry foam element, or install a new foam element.

NOTE: Always replace a foam element that is brittle, cracked,

crumbling or otherwise damaged. For best performance, routinely replace the foam element with every other engine oil change.

6. Reinstall the airbox cover. Secure all retaining clips.

Polaris FST Classic, FST Touring, FS Touring, FS Classic User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual