Polaris Fusion 900 (2005) Owner's 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 cause cancer, birth defects or

other reproductive harm.

Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2005 Fusion Owner’s Manual P/N 9919074

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 Personal Watercraft S Sport Boats 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) Technician.

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

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

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

RIDER SELECT is a trademark of Polaris Industries Inc.

TABLE OF CONTENTS

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

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

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

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

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

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

The Perfect Fit 39............................

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

Pre-Ride Inspections 53......................

This section explains procedures that must be performed before riding.

Operation 59.................................

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

Maintenance 71..............................

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

Polaris Products 109.........................

Troubleshooting 110.........................

Warranty 115................................

Index 121....................................

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 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.

Air Pollution

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

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

INTRODUCTION

Vehicle Identification Numbers

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 (1)(lower right side of the tunnel):

Engine Serial Number (on recoil housing):

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 71 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.

Riding Position

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under most 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 be properly seated and in position to control your vehicle.

SAFETY

Operator Safety

Survival Preparation

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

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

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

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 20.

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.

SAFETY

Operator Safety

Disabled Operators

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

Rider Capacity

Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger.

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 machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH, your machine will travel about 180 feet.

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

Operator Safety

Driver Awareness

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

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

SAFETY

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

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

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

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

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

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 Downhill

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

WARNING

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

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

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

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

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 machine to maintain proper balance and avoid possible roll-over.

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

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

SAFETY

Operator Safety

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 machine into motion, but always operate within safety limits.

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 machines designed to carry a load.

SAFETY

Operator Safety

Inadequate Snow Conditions

WARNING

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

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

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

CAUTION

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

SAFETY

Operator Safety

Driving Responsibly

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

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

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

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

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

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

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

S Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

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

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

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

unattended.

SAFETY

MPHHaveLittle

ClothedPerson

)

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Estimated Wind

Speed in MPH

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

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

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

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

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

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

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

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

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

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

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

Wind Speeds Greater Than 40 MPH H

vLil

Added Effect

Little Danger

(For Properly

Prn

WIND CHILL CHART (°C)

Estimated Wind Speed

inKPH

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

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

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

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

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

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

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

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

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

Increasing

Danger

Danger of Freezing Exposed Flesh

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

Great

Danger

Wind Speeds Greater

Than 70 KPH Have Little

dded E

ect

Little Danger

(For Properly

lothed Person

Increasing

Danger

Danger of Freezing Exposed Flesh

Great

Danger

SAFETY

Safety Decals and Locations

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

Pressure Cap Warning

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

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

SAFETY

Safety Decals and Locations

Track Warning

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

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

“No Passenger” Warning

The “NO PASSENGER” warning decal is on the console below the steering post:

Safety Decals and Locations

Reverse Warning

The reverse warning decal is located on the console below the windshield:

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.

SAFETY

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 lighton dash indicates reverse operation.

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

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

Operation Warning

The operation warning decal is located on the console above the storage compartments. See page 24 for the text.

SAFETY

Safety Decals and Locations

Operation Warning

Operation Warning Decal:

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

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

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

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

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

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

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

hicle.

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

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

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

clothing while operating this vehicle.

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

requirements.

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

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

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

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

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

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

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

braking ability.

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

brake engaged for more than five minutes.

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

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

Oil injectionsystem: Use unmixed fuel only. Check oillevel when refueling.

FEATURES

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Snow Flap

7. Suspension

8. Track

9. Storage Compartment

10. Rear Bumper

11. Taillights

12. Nosepan

13. Front Bumper

14. Skis

FEATURES

1. Fuel Filler Cap

2. Ignition Switch

3. Brake Lever

4. MFD Gauge

5. Headlight Adjuster

6. Engine Stop Switch

7. Throttle Control

8. Hood Hold Down Straps

9. Recoil Starter Handle

10. Headlight Dimmer Switch

11. Park Brake

12. Handlebar Grip Warmer Switch

13. Thumbwarmer Switch

14. Electronic Reverse Button

15. MFD Control

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.

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.

Setting

Comfort 1, 2 Pull the system rearward to one of the first

Control 3, 4, 5 Move the system to one of the middle three

Attack 6, 7 Push the system forward to one of the last

Position Riding Style

two positions for all-day trail riding comfort.

positions for improved handling and cornering on the trails.

two positions for easy sitting-to-standing transitions and maximum agility in rugged terrain.

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

Seat Storage Compartment

Open or close the storage compartments with the key.

Adjustable Headlights

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

Access Panel

The access panel (1) is provided for cleaning out debris and making repairs.

FEATURES

Detonation Elimination Technology (D.E.T.)

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.

DET Troubleshooting

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

Possible Cause Solution

Poor quality fuel Replace with higher quality fuel

Improper engine modifications Do not modify the engine

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 flash six times if the sensor fails

or becomes disconnected.

FEATURES

Instrumentation

MFD Component Identification

Item

1 Analog Gauge

2 Digital Gauge

3 Check Engine Indicator

4 Low Oil Indicator

5 High Temp Indicator

6 Brake Indicator

7 Reverse Indicator

8 High Beam Indicator

Digital Display Identification

Item

1 RPM or Speed

Altitude (if equipped) Service Interval

2 Electrical System Voltage

Level

3 MAX - Maximum MPH/

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

FEATURES

Instrumentation

MFD Settings

With the engine running, use the MFD Control Switch (1) to set the MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3).

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 the button is 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

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

Performance Program

The Performance Program automatically displays either speed or tachometer, whichever is opposite the analog display. See page 31. 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, entertheTrip1orTrip2display.

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

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.

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 the new setting.

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

clock will automatically save the new entry.

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).

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.

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 the 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, maximum 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.

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”.

Instrumentation

MFD Battery Replacement

FEATURES

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.

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.

FEATURES

Instrumentation

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 about 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 machine should be methodically tested, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc.) after each adjustment until the best ride is achieved.

Independent Front Suspension (IFS)

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

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

S Front shock spring preload S Compression damping (see page 41) S Optional springs S Optional shock valving (if equipped

with RydeFX or Walker/Evans shocks)

S Toe (ski alignment) (see page 103) S Camber (see your dealer)

THE PERFECT FIT

IQ Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page 103 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

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

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper (RydeFX only)

4. Body

5. Threaded Spring Preload Adjuster Nut

THE PERFECT FIT

Front Suspension Adjustments

IQ Front Shock Spring Preload

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

A=Lowpreload B = High 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.

NOTE: Always leave at least one

thread showing above the nut.

1. Grasp the spring and turn it to the left to increase preload.

2. Turn the spring to the right to decrease preload.

Shock Damping (Walker/Evans Shock)

Access the adjuster for the Walker/Evans shock behind the fender (A). Rotate the adjuster with a finger.

S Turn the adjuster clock-

wise to increase stiffness.

S Turn the adjuster counter-

clockwise to decrease stiffness.

THE PERFECT FIT

IQ Front Suspension Adjustments

Shock Valving

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

WARNING

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

Front Springs

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

IQ 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 snowcross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snowcross course.

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

Suspension Performance Tips

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

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

S In deep snow, a new slider will offer improved performance over

worn slider. It can also improve top speed.

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

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

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

your dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce

moisture and rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. Refer to Suspension Maintenance beginning on page 105.

THE PERFECT FIT

IQ Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

Take the first measurement with no rider and with the rear suspension at full extension.

NOTE: The rear bumper may need

to be lifted upward slightly to fully extend the rear suspension.

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

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration or the decal found under the hood for reference. The ideal amount of Sag for the IQ rear suspension is two inches (X-Y=2).

If the rear suspension rides in less than one inch or more than three 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

IQ Rear Suspension Adjustments

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. See your dealer for more information.

1. Soft Tension

2. Medium tension

3. Firm tension

Rear Shocks

Polaris Position Sensitive Shock

There are no external adjustments on the Polaris position sensitive (PPS) shock.

THE PERFECT FIT

IQ Rear Suspension Adjustments

Suspension Coupling

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

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

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

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

The factory setting is usually adequate for all riders and conditions.

THE PERFECT FIT

IQ Rear Suspension Adjustments

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

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

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

Rear Rear Scissor Stop (RRSS) - Attributes

Moving the RRSS to a higher position will have the following effects on the suspension:

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

THE PERFECT FIT

IQ Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting (1) is the best for most trail riding conditions.

To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position with the scissor stop tool (2) located in your tool kit.

H = High L = Low M = Medium

To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.

NOTE: Your dealer can help you with initial

setup and additional setup instructions to help you achieve your optimum ride.

THE PERFECT FIT

Handlebar Adjustments

Handlebar Position

Use the RIDER SELECT feature to adjust handlebar position. See page 27.

Handlebar Angle

Follow these steps to adjust handlebar angle at the handlebar block.

1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2).

2. Using a 7/16″ (11 mm) wrench, loosen the four nuts (3) 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

Accessories

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

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

Order PN 2870668.

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

S Non-compliance with government/industry requirements S Voiding of warranty S 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 machine 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 52.

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 outside edge of the track.

THE PERFECT FIT

Traction Products

n 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

104. If your machine 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 Wear Strip Kit P/N 2874687.

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 94, 96

Steering System 57

Recoil Rope 57

Coolant Level 84

Park Brake Lock/Brake Lever/Brake System 55, 56, 87

Auxiliary Shut-Off Switch (Engine Stop Switch) 58

Ignition Switch 58

Taillight/Brakelight/Headlight 58

Suspension Mounting Bolts 105

Skags (Wear Bars) 52, 104

Ski Saddle and Spindle Bolts 105

Hood Straps/Latches 57

Seat Latches (if equipped) N/A

Throttle Lever/Safety Switch 54, 66, 67

Rear Wheel Idler Bolts 101, 105

Tether Switch/Strap 58

age

Track Alignment/Condition 57, 99

Slider Condition 105

Chaincase Oil Level 78

Injection Oil Level NO TAG

PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING

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

Read and Understand Your Owner’s Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated. See page 66 for procedure.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Brakes

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

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 90.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 89.

Check for the presence of air in the fluid system. See page 90 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

Before Starting the Engine

n Park Brake Lever Lock

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

1. Brake Lever

2. Park Brake Lever Lock

3. Master Cylinder Reservoir / Cover

4. 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

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

The brake light in the analog 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.

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

Before Starting the Engine

n Steering System

Manually turn the skis completely to the right and to the left. If any difficulty is encountered, remove any ice and snow build-up that may be obstructing the steering linkage.

n Track

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.

n Hood Latches

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

n Recoil Rope

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

PRE-RIDE INSPECTIONS

Start the Engine and Check

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

tether from the switch to make sure the engine stops immediately.

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 the 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 machine.

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 54.

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.

3. Grasp the recoil rope handle and pull slowly until the recoil engages; then pull abruptly.

4. Repeat as needed until the engine starts.

CAUTION

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

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

OPERATION

Engine Break-In

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

CAUTION

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

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

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

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page NO TAG.

CAUTION

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

Variable Exhaust System

All snowmobile engines equipped with variable exhaust valves should use VES II 2 Cycle Oil (see chart below).

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection systems. We highly recommend the use of only Polaris products. Polaris lubricants provide the best protection for your Polaris engine.

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

Engine

Style

Liquid Cooled w/VES

Premium

2-Cycle

Good Better Best

Premium Gold

2-Cycle

VES II

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. Use a stable rear support.

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 about 4″ (10 cm) off the ground.

2. Start the engine and allow it to warm up

two to three minutes.

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

revolutions.

NOTE: It will take longer to warm up the track sufficiently during

colder outdoor temperatures.

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

the machine to the ground.

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

to loosen snow and ice.

Slide Rail and Track Cooling

CAUTION

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

Fuel

OPERATION

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

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 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 109 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

Oil

n Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.

Visually check the oil level in the bottle. Add oil before further

operation of the snowmobile. See page 61 for oil recommendations.

n Low Oil Level

Always maintain the oil level above the

tank’s low level line. This is especially

important when the machine is operated

in mountainous terrain. Maintaining the

proper oil level will prevent system

aeration and possible loss of pumping

action, which could result in engine

damage.

If necessary, the engine may be operated

as long as oil is visible in the oil tank. If

oil is not visible, continued operation

may cause serious engine damage. See

page 61 for oil recommendations.

CAUTION

Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refueling. Add oil as needed.

Always maintain an adequate supply of oil in the tank. If necessary,

the engine may be operated as long as oil is visible in the oil tank. But

if oil is not visible, continued operation may cause serious engine

damage. See page 61 for oil recommendations.

The Polaris oil cap on the oil bottle is vented to allow proper oil flow.

See your Polaris dealer for recommended replacement parts.

OPERATION

n Engine Stop Switch

Push down on the engine stop switch (A) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON 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 (B).

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

must shut down the engine.

OPERATION

Throttle Lever

WARNING

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and 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.

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

If an emergency exists and it’s necessary to start the engine, 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 machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch.

SYSTEM

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

WHAT IT DOES THROTTLE

CONDITION

Emergency Starting

If the recoil starter system fails, an emergency start strap is provided in the tool kit.

1. Open the hood.

2. Remove the left side panel.

3. Remove the air box (pull aggressively).

4. Using the belt removal tool, follow the directions on the air box to relieve belt tension.

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

WARNING

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

6. Pull the strap abruptly so the strap comes free of the clutch while starting the engine. Repeat until the engine starts.

7. Reinstall the air box and side panel.

8. Close and secure the hood.

OPERATION

Electronic Reverse (PERC

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

WARNING

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

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

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

NOTE: The maximum engine RPM will be 6000 when in reverse.

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

gear when it’s restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off.

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

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 machine.

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

CAUTION

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

MAINTENANCE

Polaris Recommended Maintenance Program

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

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

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

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

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

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.

MAINTENANCE

Periodic Maintenance Interval Table

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

See Frequency

Item

Clutch Offset Alignment (without belt)

Drive Belt Condition 94 I I I I

Clutches (disassemble) 93 C C C

Belt Tension -- I I I I

Clutch Sheaves 93 I I I I

Engine Mounts -- I I I I

Recoil Rope -- I I I I

Engine Torque Stop 96 I I I I

Cylinder Head Bolts -- I I I

Cylinder Base Nuts -- I I I I

Ignition Timing BTDC -- I I I

VES System -- C C C I

Coolant Level 84 I I R I

Coolant Hose -- I I I I

Heat Exchangers 85 I I I I I

Coolant Circulation -- I I I

Coolant Leaks -- I I I I

Spark Plug Condition 80 I I I R I

Exhaust Pipe 83 I I

Exhaust Retaining Springs

Page

83 I I I I

150 mi.

(240 km)

CLUTCH

ENGINE

500 mi.

(800 km)

I I I

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

Periodic Maintenance Interval Table

See Frequency

Item

Hose Routing -- I I I I

Hose Condition -- I I I I

Fluid Leaks -- I I I I

Brake Pads 87 I I I I

Brake Disc -- I I I I

Parking Brakes 56 I I I I

Brake System 54, 87 I

Brake fluid 89 R

Idle RPM -- I I I

Throttle Lever 54, 67 I I I I I

Oil Pump Lever (synchronize)

Page

150 mi.

(240 km)

BRAKES

FUEL MANAGEMENT

500 mi.

(800 km)

I I I

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Throttle Cable 77 L L L

Vent Lines -- I I I I

Throttle Position Sensor -- I I I

Fuel Lines 81 I I I I I

Oil Filter 82 R R

Oil Lines 82 I I I

Air Box -- I I I I I

ELECTRICAL

Auxiliary Shut-Off Switch 58 I I I I I

Throttle Safety Switch 54, 66 I I I I I

Ignition Switch -- I I I I I

Taillight 58 I I I I I

Brakelight 58 I I I I I

Headlight 58 I I I I I

MAINTENANCE

Periodic Maintenance Interval Table

See

Item

Ski Toe Alignment -- I I I

Suspension Mounting Bolts

Steering Fasteners -- I I I I C

Rear Suspension Fasteners

Suspension Shock Oil -- I I I I

Cooling Fins and Shroud -- I I I I

Drive Shaft Bearings 77 L L L I

Jackshaft Bearings 107 L L L I

Skags (Wear Bars) 51 I I I I I

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

Drive Chain Tension 86 I I I I I

Hood Straps 57 I I I I I

Rear Wheel Idler Bolts 101 I I I I I

Idler Bolt Jam Nut 101 I I I I I

Rear Suspension Pivot Shafts

Page

150 mi.

(240 km)

CHASSIS

I I I I I

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

L L L

2000 mi.

(3200 km)

Pre-

Season

Camber Alignment -- I I I

Handlebar Centering -- I

Tether Switch and Strap 58 I I I I I

Track Alignment 99 I I I I I

Track Tension 100 I I I I I

Front Limiter Strap -- I I I I I

Slider Condition 105 I

Chaincase Oil 78 I I I R I

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

MAINTENANCE

Maintenance Log

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

150 Mile (240 km) Initial Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

500 Mile (800 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

1000 Mile (1600 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

2000 Mile (3200 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

MAINTENANCE

Maintenance Log

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

MAINTENANCE

Lubrication

Front Suspension

The Fusion front suspension and steering components do not require lubrication.

Rear Suspension

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

Driveshaft Bearing

Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

Throttle Cable

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

MAINTENANCE

Lubrication

n Chaincase Oil

Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 72. Maintain the oil level between the safe marks on the dipstick (A). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

NOTE: Clean the magnetic plug (B) whenever checking or changing

lubricant.

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 109 for the part numbers of Polaris products.

Oil Check

1. Position the machine on a level surface.

2. Remove the dipstick and wipe it clean with a dry cloth.

3. Reinstall the dipstick, then remove it and read the oil level.

4. Add the recommended oil as needed. Do not overfill.

5. Reinstall the dipstick, making sure it is seated properly.

Oil Change

1. Position the machine on a level surface.

2. Place a drain pan beneath the chaincase and remove the drain plug (C). Allow the oil to drain completely.

3. Install a new sealing washer on the drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank

should be clean and free of burrs, nicks or scratches.

4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

5. Remove the dipstick and wipe it clean with a dry cloth.

6. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.

7. Reinstall the dipstick, making sure it is seated properly.

MAINTENANCE

General Maintenance

Spark Plugs

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

Change the spark plugs every 2000-2500 miles (3200-4000 km).

CAUTION

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

S Use recommended spark plugs with the proper gap. S Use only resistor-type spark plugs. S Torque spark plugs to 18-22 ft. lbs. (24-30 Nm). S Always carry spare spark plugs.

MAINTENANCE

General Maintenance

Spark Plugs

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

WARNING

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

1. Normal

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

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

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

2. Wet Fouled

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

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

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

3. Reverse the procedure for spark plug installation.

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

5. Reinstall the spark plug cap.

General Maintenance

Intake Filter

MAINTENANCE

The intake foam filter (1) limits snow ingestion into the intake system. When operating in loose powder snow, check the foam filter periodically to remove any accumulation of snow.

Fuel Injectors

All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors.

Fuel Pump

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

Fuel Lines

Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.

CAUTION

Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.

MAINTENANCE

General Maintenance

Oil Filter

Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch.

Have your dealer perform the filter change and bleeding operation.

NOTE: The direction of the

arrows indicates the direction of flow through the filter.

MAINTENANCE

General Maintenance

Exhaust System

Check the exhaust system for wear or damage at approximately 2000

miles (3200 km). To inspect, allow the engine and exhaust system to

cool completely. Open the hood and inspect the muffler and pipes for

cracks or damage. Check for weak or missing retaining springs or

damper/support grommets.

WARNING

Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

Coolant

The coolant supplied in the system is a 50/50 mixture of

ethylene-glycol and distilled water. This mixture provides protection

against freezing at temperatures to -34° F (-37° C). If greater

protection is required, the percentage of antifreeze to water may be

increased. Use Premium 60/40 anti-freeze coolant, which is already

premixed and ready to use. Do not dilute with water. Never exceed a

60% antifreeze/40% water mixture. Contact your dealer if greater

protection is required. See page 109 for Polaris products.

NOTE: Never add tap water to the cooling system. Minerals cause

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

MAINTENANCE

General Maintenance

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by a switch in the ECU. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. See your dealer.

n Coolant Level

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

S Coolant bottle or overflow tank S Engine filler neck S Pressure cap S Connecting hoses

Always maintain the coolant level between the minimum and maximum marks on the coolant bottle (when engine is cold) to prevent overheating and serious engine damage.

CAUTION

Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage. Always maintain the coolant level as recommended.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

MAINTENANCE

General Maintenance

Bleeding the Cooling System

Use of a non-standard pressure cap will not allow the recovery system

to function properly. If the pressure cap needs replacement, contact

your dealer for the correct part.

WARNING

Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.

CAUTION

If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.

1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark.

2. Elevate the front end of the machine slightly to aid in bleeding of the heat exchangers.

3. Remove the bleed screw from the water outlet manifold and/or the thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

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

5. Start the engine and run at a fast idle for two to three minutes. Loosen the bleed screw occasionally to purge any trapped air.

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

7. Feel the heat exchangers under the running boards. If the system is bled properly, they’ll be warm to the touch. If they’re not, repeat step 5. Lift the front of the machine slightly to assist in the bleeding.

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

MAINTENANCE

General Maintenance

Drive Chain Tension

Check drive chain tension weekly and before each long trip. To obtain correct chain tension:

1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

2. Loosen the adjuster bolt jam nut (A).

3. Finger tighten the adjuster bolt (B) until it can no longer be adjusted by hand, then back off 1/4 turn.

4. Tighten the jam nut while holding the adjuster bolt. Torque to 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

MAINTENANCE

General Maintenance

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile.

Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm).

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″). A kit is available for replacing brake pads. See your dealer.

WARNING

Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety. Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive.

Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16″).

MAINTENANCE

General Maintenance

Brake Components

1. Brake Caliper

2. Brake Disc

3. Backing Plate

4. Brake Pad Material (Replace when thickness is less than 1/16″/1.5mm).

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 87), bring the machine to an authorized Polaris dealer for inspection and adjustment.

General Maintenance

Brake Fluid

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury.

WARNING

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

CAUTION

MAINTENANCE

Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately.

Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 109 for the part numbers of Polaris products.

The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid.

MAINTENANCE

General Maintenance

Bleeding the Hydraulic Brake System

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

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX marks or 1/4-5/16″ (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock, resulting in serious injury or death. Always add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level. Seepage89.

8. Reinstall the gasket and cover.

MAINTENANCE

General Maintenance

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin

leaves a residue, causing a hot spot that will shorten the life of the lamp.

Removing Halogen Bulbs

1. Remove the plenum covering from the headlight assembly.

2. Lift the rubber boot to expose the bulb.

3. Push down on the spring (1) to release it from the housing.

4. With the wire harness (2) attached to the bulb (3), withdraw the bulb from the housing.

5. Grasp the bulb by its metal base and carefully separate the bulb from the harness.

Installing Halogen Bulbs

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

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Verify headlight aim.

MAINTENANCE

General Maintenance

Taillight/Brakelight Replacement

1. Open the rear storage compartment.

2. Reach into the compartment and locate the socket assembly above the door opening.

3. Turn the socket counterclockwise 1/4 turn.

4. Carefully pull the socket assembly away from the taillight.

5. Replace the bulb and reinstall the socket assembly.

MAINTENANCE

General Maintenance

Clutch System

WARNING

If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.

CAUTION

The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.

Clutch Alignment and Offset

Clutch alignment offset (A) is important for maintaining optimum performance. See your Owner’s Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed.

Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. Polaris recommends the use of O.E.M. belts. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. See your dealer for service and adjustments.

NOTE: A worn belt will continue to function, but

will not deliver maximum performance. Always carry a spare belt in case of an emergency.

MAINTENANCE

General Maintenance

n Drive Belt Condition

Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.

For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile.

Drive Belt Removal

1. Be sure the key switch is off and the engine has come to a complete stop. Apply the brake (or lock the parking brake if equipped).

2. Open the hood. Remove the left side panel to access the drive clutch.

3. Locate the L-wrench in the tool kit. Install the wrench into the open threaded hole in the outer sheave of the clutch (A).

4. Turn the wrench clockwise until the sheaves open far enough to remove the belt.

MAINTENANCE

General Maintenance

Drive Belt Installation

1. Drop the drive belt over the drive clutch and pull back the slack.

NOTE: To ensure satisfactory belt

life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the belt removal procedures.

2. Rotate the L-wrench counter-clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves.

3. Remove the wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

MAINTENANCE

General Maintenance

n Drive Belt Deflection

Measure belt deflection with both clutches at rest and in their full neutral position.

Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4” (3.2 cm).

Drive Belt Adjustment

TEAM Clutch

1. Loosen the 7/16” jam nut on the belt width adjuster.

2. Using a 1/8” Allen wrench, adjust the threaded set screw as needed.

NOTE: Turn the set screw in (clockwise) to increase the distance

between the sheaves and out (counterclockwise) to decrease the distance.

3. Tighten the jam nut.

Torque Stop

Periodically check torque stop (1) clearance. With clutches in proper alignment, the clearance should be .010″-.030″ (.25-.75mm) from the engine case. Adjust if necessary. Lock the jam nut.

.010″-.030″ (.25-.75mm)

General Maintenance

Tool Kit

MAINTENANCE

A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile.

1. Emergency Start Strap

2. Phillips Screwdriver

3. L-Wrench

4. Spark Plug Wrench

5. Wrench

6. Flat Screwdriver

7. Scissor Stop Wrench

8. Box End Wrench

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition.

Maintenance Items

The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer.

Polaris Fusion 900 (2005) Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual