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.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at Polaris we proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• 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 complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 Indy 340 Touring/Trail Touring/600 EDGE Touring/WideTrak Owner's Manual
P/N 9919669
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 30
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 134
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 135
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 152
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3
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:_____________________________________________________________
(lower right side of the tunnel)
Engine Serial Number: ____________________________________________________
(right front side of engine crankcase)
Key Number: ___________________________________________________________
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.
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.
4
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education campaign. We encourage governments 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.
5
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.
6
SAFETY
Operator Safety
Follow the recommended maintenance program beginning on page 80
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.
7
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.
8
SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, but under many conditions, the proper position is to
be seated with both feet on the running boards and both hands on the
handlebar grips for proper throttle, brake and steering control.
NOTE: Use of a backrest may hinder your weight shifting ability. This
Improper riding position may reduce control and could result in serious injury
or death. Always ride in a position that allows for control of your vehicle.
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 21.
could affect your ability to control this rider-active vehicle in certain extreme driving situations.
WARNING
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.
9
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:
• Spare Drive Belt • Winter Survival Kit
• Extra Set of Spark Plugs • Trail Map
• Tow Rope • Owner's Manual
• Extra Oil • First Aid Kit
• Fuel Deicer
10
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.
Cargo Overload
Too much weight on the rear of the machine may reduce your ability to
steer. Do not exceed carrier and rack weight limits, and do not allow a
passenger to sit on the seat back or the cargo carrier.
WARNING
Control becomes more difficult with two people on board. More space is
required to make turns, and longer distances are needed for stopping. Make
sure the passenger remains seated behind the driver, facing forward, with
both feet placed firmly on the running boards. Slow down and avoid “jumping" your snowmobile.
Rider Capacity
Driving 1-Up - Some Polaris snowmobiles are designed for a single
rider only. A decal on the console of these models indicates single rider
operation.
Driving 2-Up - Some Polaris snowmobiles are designed for up to two
riders. A decal on the hood of these models indicates that the vehicle is
designed for one operator and one passenger only. See page 23 for
decal location.
Machines designed for two riders should never be operated with more
than two people on board. When traveling with a passenger, it's the
driver's responsibility to operate the machine safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are necessary
for stopping.
11
SAFETY
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious injury or death.
Always reduce speed when driving at night or in inclement weather.
Always observe all 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 in two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don't over-drive your headlight beam.
Always be able to bring your machine to a stop in the distance illuminated by the headlight.
12
SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you're snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or highways. Steep embankments may also hide
your view. Always leave yourself a way
out.
Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Avoid travelling on frozen bodies of water.
RR
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.
13
SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• 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.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at
www.avalanche.org.
14
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
Driving on ice or hard-packed snow reduces steering and braking control,
which may result in loss of control and serious injury or death. Never attempt
an abrupt change of direction when operating on slippery surfaces. Slow
down and use extra caution when operating on slippery surfaces.
15
SAFETY
Operator Safety
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.
16
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.
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.
17
SAFETY
Operator Safety
Clutch Guard
Do not operate the engine with the clutch guard removed.
The clutch guard is designed to protect the operator from metal parts if
the clutch should fail. Although the chance of failure is extremely
remote, don't defeat the purpose of the safety guard by removing it.
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.
Maintenance
Follow the recommended maintenance program beginning on page 80
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.
18
SAFETY
Operator Safety
Inadequate Snow Conditions
Moveable hood closures are included on some Polaris snowmobiles.
They are normally left open and are located on the front upper and lower
hood openings. If operating in deep snow or in extreme cold conditions
(below -20_ F), Polaris recommends closing the upper hood closure.
WARNING
Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could
cause irreversible track damage and lead to serious 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.
19
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.
• A snowmobile depends on the rider's body position for proper balance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
• Before allowing someone else use your snowmobile, know the extent
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.
• Don't "jump" your snowmobile. Jumping may injure your back
because 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.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• When traveling in a group of snowmobiles, don't tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.
• Remove the key from the ignition when you leave the snowmobile
unattended.
20
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
WINDCHILL CHART (_F)
Wind
Speed
40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
in
MPH
Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15
5 3631251913 7 1 -5-11-16
10 34 27 21 15 9 3 -4 -10 -16
15 32 25 19 13 6 0 -7 -13
20 30 24 17 11 4 -2 -9 -15
25 29 23 16 9 3 -4 -11 -17
30 28 22 15 8 1 -5 -12
35 28 21 14 7 0 -7 -14
40 27 20 13 6 -1 -8 -15
45 26 19 12 5 -2 -9 -16
50 26 19 12 4 -3 -10 -17
55 25 18 11 4 -3 -11
60 25 17 10 3 -4 -11
Frostbite in >>
Actual Thermometer Reading (_F)
Equivalent Temperature (_F)
-20 -25 -30 -35 -40 -45
-22 -28 -34 -40 -46 -52 -57 -63
-22 -28 -35 -41 -47 -53 -59 -66 -72
-19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-22 -29 -35 -42 -48 -55 -61 -68 -74 -81
-24 -31 -37 -44 -51 -58 -64 -71 -78 -84
-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
-21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
-18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
-19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
30 min. 10 min. 5 min.
WINDCHILL CHART (_C)
Wind
Speed
5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
in
KPH
Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28
8 3 0 - -7 -11 -14 -18 -22 -25 -29
16 2 -2 -6 -10 -13 -17 -21 -24 -28
24 1 -3 -7 -11 -15 -19 -22 -26
32 0 -4 -8 -12 -16 -20 -24 -28
40 -1 -5 -9 -13 -17 -21 -25 -29
48 -1 -5 -9 -13 -18 -22 -26
56 -2 -6 -10 -14 -18 -22 -26
64 -2 -6 -10 -15 -19 -23 -27
72 -2 -7 -11 -15 -19 -23 -28
80 -3 -7 -11 -15 -20 -24 -28
88 -3 -7 -12 -16 -20 -24
96 -3 -8 -12 -16 -21 -25
Frostbite in >>
Actual Thermometer Reading (_C)
Equivalent Temperature (_C)
-32 -36 -39 -43 -46 -50 -53 -57
-32 -36 -39 -43 -47 -50 -54 -58 -62
-30 -34 -38 -42 -45 -49 -53 -57 -61 -65
-32 -36 -39 -43 -47 -51 -55 -59 -63 -67
-33 -37 -41 -45 -49 -53 -57 -61 -65 -69
-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
-32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
-29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
-29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
30 min. 10 min. 5 min.
-31 -34 -37 -40 -43 -46
21
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:
WARNING
Do not operate engine with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with plenum/belt guard removed.
Never run engine with drive belt removed.
Never service clutches yourself -- see your dealer.
Airbox Warning
This warning decal is found under the hood on applicable models:
CAUTION
Do not operate above 40 mph with hood-to-airbox foam removed
or engine failure will result.
Pressure Cap Warning
This warning decal is found on the coolant bottle cap of liquid cooled
models:
WARNING
Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI
22
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 can
result in severe injury or death.
Passenger Warning
Polaris touring models and the
WideTrak are designed for the
operator and one passenger. For
more information on operating
with a passenger, see page 11.
The passenger warning decal is
located at the right side of the
steering post:
WARNING
This vehicle is designed for
operator and ONE passenger
only.
SAFETY
✪
✪
23
SAFETY
Safety Decals and Locations
Standard Reverse Warning
The Polaris WideTrak snowmobile is equipped with standard reverse. The reverse
warning decal is located
above the instrument housing:
WARNING
Reverse operation, even at
low speeds, can cause
loss of control resulting in
serious injury or death. To
avoid loss of control,
always:
• Look behind before and
while backing up.
• Avoid sharp turns.
• Shift to or from reverse only when stopped.
• Apply throttle slowly.
For more information, see Owner's Manual.
✪
24
SAFETY
Safety Decals and Locations
Electronic Reverse Warning
Polaris snowmobiles equipped
with electronic reverse have a
reverse warning decal on the
lower dash:
WARNING
Reverse operation, even at low
speeds, can cause loss of control resulting in serious injury
or death. To avoid loss of control, always:
• Look behind before and
while backing up.
• Avoid sharp turns.
• Shift to or from reverse only
when stopped.
• Apply throttle slowly.
For more information, see Owner's Manual.
If electric reverse:
• Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse operation.
• Push button again to return to forward.
• 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.
✪
25
SAFETY
Safety Decals and Locations
Operation Warning
The operation warning decal is located on the console:
• To avoid serious injury or death, read and understand all warnings
and the Owner's Manual before operation. If manual is missing, contact a Polaris dealer for a replacement.
• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.
• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.
• Never consume alcohol or drugs before or while operating this vehicle.
• 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.
• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
• This vehicle is designed for adult use only. Check local laws for age
requirements.
• 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.
• 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.
• 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.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• 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 injection system: Use unmixed fuel only. Check oil level when
refueling.
26
FEATURES
Some Polaris snowmobiles are equipped with special features. Operating controls and special feature controls are illustrated on this page. Not
all models come with all special features. See your Owner's Manual
Supplement.
6
5
4
7
8
9
10
3
2
1
1. Fuel Filler Cap
2. Ignition Switch
3. Accessory Plug
4. Brake Lever
5. Electronic Fuel Gauge
6. Speedometer
7. Tachometer
8. Electric Shock Control Gauge
9. Engine Stop Switch
10. Throttle Control
11. Hood Hold-Down Straps
12. Recoil Starter Handle
13. Choke
14. Headlight Dimmer Switch
15. Park Brake Lock
16. Handlebar Grip Warmer Switch
17. Thumbwarmer Switch
18. Electronic Reverse Button
19. Electronic Shock Control Button
12
11
13
14
16
19
16
15
Touring Models
14
17
18
WideTrak
27
FEATURES
3
8
7
4
6
5
9
19
2
10
1
11
13
18
14
12
15
17
16
20
OFF
HIGH
LOW
28
FEATURES
1. Hood
2. Headlight
3. Passenger Lumbar
Adjuster (Touring)
4. Windshield
5. Handlebar
6. Operator Seat
7. Passenger Seat
8. Trunk Cover
9. Taillights
10. Rear Bumper
11. Snow Flap
12. Passenger Grab Handle
13. Track
14. Suspension
15. Trailing Arm
16. Nosepan
17. Front Bumper
18. Skis
19. Grab Handle Heater
Switch
20. Passenger Hand Hold
Strap (WideTrak)
29
THE PERFECT FIT
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.
IFS Components
1. Skis
2. Front shocks and springs
3. Rod ends
4. Trailing arms
IFS Adjustment Options
• Shock damping (if equipped
with Indy Select shocks)
• Front shock spring preload
• Optional springs
• Optional shock valving (if equipped with RydeFX shocks)
• Toe (ski alignment) (see page 122)
• Camber (see your dealer)
4
1
2
3
30
THE PERFECT FIT
Front Suspension Adjustments
WARNING
Always verify ski alignment before making adjustments to the IFS. See page
122 to check alignment. If the skis are misaligned, see your dealer, as the
camber adjustment may also be affected.
For the best ride, the suspension should be adjusted to use the full travel
of the shocks with occasional light bottoming. To determine if your
machine is using full travel, push the jounce bumper down on the shock
rod until it contacts the body and test ride the machine. The bumper will
move up on the rod in relation to the amount of travel that was used during the ride. If the travel is full, the bumper will be seated at the top of
the rod.
Shock Components
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.
1
2
3
1. Retainer
2. Shock Rod
3. Jounce Bumper
4. Body
5. Threaded Spring Preload Adjuster Nut
4
5
31
THE PERFECT FIT
Front Suspension Adjustments
Shock Damping (Indy Select Shock)
Adjustments to the compression stiffness of Indy Select shocks can be
made by turning the adjustment screw
located near the base of the shock (✪).
This adjustment is the easiest to perform and it should be considered first.
The factory setting for this shock is the
softest position, with the adjusting
screw all the way out (counterclockwise). If bottoming occurs, the Indy
Select feature should be used to achieve the desired ride. The shocks
have a wide range of adjustment capability. By turning the screw clockwise, the compression of the shock increases, stiffening the ride. When
adjusting these shocks, we recommend that you turn the screw only 1/4
turn at a time, then test ride. Always adjust both shocks equally.
✪
32
THE PERFECT FIT
Front Suspension Adjustments
Spring Preload
Increasing spring preload will increase
ski-to-ground pressure. Decreasing
spring preload will decrease ski-toground pressure. When adjusting, be
sure the springs on both the left and right
sides of the machine are at the same
adjustment.
To increase front shock spring preload,
grasp the spring and turn it to the right.
Turn it to the left to decrease preload.
Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch of
preload beyond the factory settings, and
Low
Preload
ensure that both sides are adjusted the
same. When decreasing preload, make sure at least two turns of preload
are holding the spring between the retainer on top of the shock and the
threaded spring preload adjuster nut on the shock body.
NOTE: Not all models have shocks with thread adjustable spring pre-
load. See your dealer for more information.
High
Preload
CAUTION
Always leave one thread showing above the adjuster nut. On models
equipped with a plastic adjuster nut, if the nut is unscrewed from the
threaded body, the nut will break.
33
THE PERFECT FIT
Front Suspension Adjustments
Shock Valving
RydeFX 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 shocks requires special tools and a
sound knowledge of mechanical theory, tool use, and shop procedures to
perform the work safely and correctly. Shocks contain high-pressure nitrogen
gas. Use extreme caution when handling high-pressure service equipment.
We recommend that this work be performed by a Polaris dealer.
Front Springs
For models without externally adjustable or revalvable shocks, the front
springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your
Polaris dealer for more information.
34
THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and deliver
excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off.
For example, a suspension set up for 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.
Refer to the suspension setup label on your snowmobile, or see your
Polaris dealer for initial suspension setup information. Additional
adjustments can be made after initial setup. Make adjustments to one
area at a time so you can evaluate the change. For further assistance, see
your dealer.
35
THE PERFECT FIT
Rear Suspension Adjustmments
Suspension Performance Tips
• Rider weight usually determines the position at which the spring preload 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.
• In deep snow, a new rail slide will offer improved performance over
worn rail slide. It can also improve top speed.
• 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.
• 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. See page 84.
Track Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 118.
36
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
Initial Spring Preload Setting (Sag Method)
To set up the EDGE rear suspension
torsion spring preload, measure the
distance between the ground and
rear bumper. This is measurement
X.
Take the first measurement with no
rider and with the rear suspension at
full extension.
NOTE: The rear bumper may need
to be lifted upward slightly
to fully extend the rear suspension.
Next, have the rider drop down
hard on the seat and bounce up and
down several times, collapsing the
rear suspension. With the rider
seated, measure the distance
between the ground and the rear
bumper at the exact location used
for measurement X. This is measurement Y.
To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). Adjust sag by rotating the torsion spring
preload cams located on the rear torque arm. Use the illustration for reference. The ideal amount of Sag for the EDGE rear suspension is four
inches (X-Y=4).
If the rear suspension rides in less than three inches or more than five
inches with the torsion spring preload cams at their maximum range of
adjustment, optional torsion springs (softer or stiffer, respectively) may
be required. This is only an initial set-up, and final spring preload may
vary based on rider preference and riding conditions.
X
Y
37
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
Rear 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.
The following information is provided only as a guideline to be used for
initial suspension set-up. Your set-up may vary based on your desired
riding style.
Low Tension Medium Tension High Tension
38
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
Indy Select Rear Shock
Some snowmobiles are equipped with the Indy Select rear shock, which
allows for adjustments to the compression valving. Locate the adjustment screw near the base of the shock. In half-turn increments, turn the
screw clockwise to increase compression valving and stiffen the ride, or
counterclockwise to reduce compression and soften the ride. There are
approximately three full turns of adjustment available.
If bottoming continues after the screw has been turned fully clockwise,
the torsion spring should be adjusted (see page 38). Return the screw to
its original starting position after the torsion spring has been tightened.
Adjustment Screw
39
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
Optional Coil Springs
Different rate coil springs are available for some shocks if a firmer ride
is desired. Contact your dealer for more information.
Suspension Coupling
On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each
other. Rear suspension coupling links the movement of the front and
rear torque arms to each other. There are two types of rear suspension
coupling.
Front 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 reducing kickback.
The factory setting is usually adequate for all riders and conditions.
40
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
Suspension Coupling
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.
Moving the RRSS to a higher position will have the following effects on
the suspension:
• Reduced weight transfer.
• Improved chatter bump ride.
• Improved cornering performance.
41
THE PERFECT FIT
EDGE 136 Rear Suspension Adjustments
(Indy 340 Touring)
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 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
located in your tool kit.
To increase weight transfer or ski lift
during acceleration, move the RRSS
to the rearward hole on high position. The RRSS may also be rotated
to a lower position for even more
weight transfer if desired.
Stock Position - This setting is most
desirable for trail riding.
Scissor
Stop
To o l
Stock
Medium or High Position (standard
hole location) - This setting will
decrease weight transfer.
Rearward Upper Position
(optional hole location - This setting
will increase weight transfer.
NOTE: Your dealer can help you
with initial setup and additional setup instructions to
help you achieve your optimum ride.
42
Medium/High
Rearward Upper
THE PERFECT FIT
EDGE Touring Suspension (ETS) Adjustments
Torsion Springs
Two torsion springs are used on the rear arm of
the ETS. Preload adjustments can be made by
turning the rectangular adjusters with a spark
plug wrench.
The firm torsion spring should be used if frequent bottoming is encountered during two up
riding on rough trails.
The soft torsion spring should be used for frequent one up riding on smooth trails.
Soft Tension
For soft tension, position the long end of the
cam to the front. For firm tension, position the
long end of the cam up.
Front Track Spring and Preload
Front track spring and preload can also be
adjusted. Turn the screw clockwise to
tighten compression (stiffen). Turn the
spring clockwise to tighten preload.
Initial Setup Reference Chart
This chart is only a guideline for initial suspension setup. Your setup may vary based
on your desired riding style.
1 Rider Soft
Firm
2 Riders Soft
Firm
Lefthand Righthand
To r s i o n
Spring &
Block Setting
Low
Med
Med
High
Optional Torsion Spring Optional Front Track Spring
RCA
Position
1-2
2-3
3-4
4-5
Front Track
Spring Preload
1.00 max
Screw
(Inches)
0.25
0.50
0.75
Firm Tension
Spring
Front Track
Indy Select -
Turns From
Full Open
0-1
1-2
1-3
2-3
Soft
Firm
7042139-067
7042282-067
7042140-067
7042283-067
7041351-067
-------
43
THE PERFECT FIT
EDGE Touring Suspension (ETS) Adjustments
The following information has been compiled to assist you in tuning
your ETS to its maximum potential.
The Ride Control Adjuster (RCA)
1. Refer to the initial setup reference chart (located under the hood of
your snowmobile and on page 43) to determine the desired RCA
position.
2. To adjust, loosen the hex bolts attaching the rear lower shock cross
shaft to the rail beam. See illustration.
3. Using a 9/16" wrench, loosen the jam nuts on the preload bolts.
4. Adjust the preload bolts to the desired RCA position.
5. Tighten the jam nuts.
NOTE: Make sure the preload bolt contacts the slide block before tight-
6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).
NOTE: The RCA setting is the primary rear suspension adjustment. It
ening the jam nut.
will have the MOST effect on rear suspension performance.
44
Hex Bolt
Preload Bolt
Jam Nut
THE PERFECT FIT
EDGE Touring Suspension (ETS) Adjustments
Front Arm Mounting Holes
There are also two front arm mounting holes in the slide rail that can
adjust ski pressure. The lower hole increases ski pressure while the
upper hole decreases ski pressure.
Decrease
Increase
pressure
pressure
45
THE PERFECT FIT
WideTrak Rear Suspension Adjustments
Rear Spring Settings
Rear spring adjustment is primarily a control for riding comfort. To
check for the recommended settings:
1. Lift the rear of the machine to relieve the rear springs.
2. Slowly lower the machine and measure the distance between the
ground and the running board.
3. Without letting the suspension settle, the rider should carefully
mount the snowmobile.
4. Measure the distance between the ground and the same spot on the
running board.
The difference between the two measurements should be approximately
1 1/2" (3.8 cm). If the difference is greater than 1 1/2", the rear spring
should be adjusted equally on both sides until the desired 1 1/2" drop is
obtained.
Compensating adjustments for heavy or light drivers or cargo loads can
be made by adjusting the rear spring eye bolt length. Adjust spring tension so there is equal tension on the long leg of each spring.
Eye Bolt
NOTE: Rear spring settings will affect ski-to-ground pressure. If ski
46
pressure is too light it may be desirable to tighten the rear
springs for an increase in ski-to-ground pressure.
THE PERFECT FIT
Handlebar Adjustments
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 7/16I (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
fuel 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.
1
2
3
47
THE PERFECT FIT
Passenger Grab Handle Adjustment
On some Touring models the
position of the passenger grab
handles can be adjusted for rider
preference.
1. Unscrew and remove the
knob assemblies that secure
the grab handles.
2. Reposition the grab handles
to one of the three available
positions on the grab handle
tube between the operator
seat and the passenger seat.
3. Reinstall the knob assemblies
and tighten securely.
Knob
Assembly
48
THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.
Use only Polaris parts and accessories on your Polaris snowmobile. Use
of unapproved parts and accessories may result in:
• Non-compliance with government/industry requirements
• Voiding of warranty
• 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.
49
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. See your
dealer about installing studs and/or carbides. Many tracks with deep lug
designs cannot be studded, but your dealer will be able to offer advice
and assistance.
NOTE: Polaris does not recommend the use of traction products on
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.
WideTrak snowmobiles.
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. The center of
the stud must be at least 1 1/8
50
I (2.86 cm) from the outside edge of the track.
THE PERFECT FIT
Traction Products
nCarbide 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 123.
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.
Inspect skags and studs frequently. Worn studs or skags may reduce
steering and braking control on hard-packed snow and ice. Replace
worn studs and skags to maintain proper balance and vehicle control.
WARNING
Loss of control can result in serious personal injury or death. Proper balance
of traction products on the skis and track must be maintained to obtain proper
vehicle control on hard-packed snow or ice. See your dealer for assistance.
51
THE PERFECT FIT
Traction Products
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. See your dealer for more information.
Some models are manufactured with tunnel wear strips or wear strip
coolers installed. Wear strips are designed for a specific stud length. See
your dealer's studding chart for recommended traction accessories.
Components (viewed from rear of track)
1. Top of tunnel
2. Wear strip
3. Track
4. Wear strip mounting holes
1
2
4
3
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.
52
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to
locate the pre-ride inspection items.
Item See Page
Drive Belt Condition 111, 114
Steering System 57
Recoil Rope 58
Coolant Level 99
Park Brake Lock/Brake Lever/Brake System 55, 56, 103
Auxiliary Shut-Off Switch (Engine Stop Switch) 59
Ignition Switch 59
Taillight/Brakelight/Headlight 59
Suspension Mounting Bolts 125
Skags (Wear Bars) 123
Ski Saddle and Spindle Bolts 125
Hood Straps/Latches 58
Seat Latches (if equipped) 58
Throttle Lever/Safety Switch 70, 71
Rear Wheel Idler Bolts 119
Tether Switch/Strap 59
Track Alignment/Condition 57, 120
Rail Slide Condition 124
Chaincase Oil Level 90
Injection Oil Level 67
53
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 70.
54
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Hydraulic 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 1/2I (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 105 or see your dealer for service.
NOTE: If the brake lever feels “spongy” when squeezed, check the
brake fluid level and condition. Add fluid as needed. See page
104.
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.
1/2I (1.3 cm)
n Mechanical Brakes
Always check the following items for proper operation before starting
the engine.
Brake Lever Travel
Firmly depress the brake lever.
Measure the distance (A)
between the lever and brake
block. The distance should be
no more than 3/4I (1.9 cm).
If the distance is greater than
this recommendation, the brake
cable must be adjusted.
3/4I (1.9 cm)
55
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Park Brake Lever Lock
If your model is equipped with the park brake lever lock, use the 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 (if
3
2
4
equipped)
3. Master Cylinder Reservoir/
1
Cover
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze the brake lever tightly and push forward on
the lock. Hold the 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 on the console 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 and release it. 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.
56
PRE-RIDE INSPECTIONS
Before Starting the Engine
n Steering System
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.
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.
57
PRE-RIDE INSPECTIONS
Before Starting the Engine
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 Seat Latches
If your snowmobile is equipped with a removable seat, ensure that the
seat latches are securely in place before every use of 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.
n Transmission
Make sure the transmission is not in reverse before starting the engine
(if equipped with reverse).
58
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 Te th e r S w it c h
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.
59
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 Before Starting the Engine
beginning on page 54.
1. Turn the fuel valve on. See page 64.
2. Turn the key to the ON position.
CHOKE TOGGLE
POSITIONS
3. Pull the engine stop switch up to the
RUN position.
OFF
4. If starting a cold engine, flip the
choke toggle to FULL ON. Do not
use the choke if starting a warm
HALF ON
engine.
NOTE: Do not depress the throttle until
the engine starts.
FULL ON
WARNING
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.
5. If equipped with electric start, turn the key to START to crank the
engine. Release the key to the ON position when the engine starts.
6. If not equipped with electric start, grasp the recoil rope handle and
pull slowly until the recoil engages; then pull abruptly to crank the
engine.
7. Repeat the cranking procedure as needed until the engine starts.
8. After the engine starts, flip the choke toggle to the OFF position. If
the engine slows or wants to stop, use intermittent choking to the
HALF ON position.
60
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 fuel 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.
61
OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. See page 67.
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.
Oil Recommendations
Engine lubrication comes from oil added to the fuel and oil injection
systems. On Polaris snowmobiles equipped with a variable exhaust system (VES), Polaris highly recommends the use of only VES II 2 Cycle
Oil. See the table below for additional oil recommendations. See page
134 for the part numbers of Polaris products.
Engine
Style
Fan Cooled Good Better N/A
Liquid Cooled Good Better N/A
Liquid Cooled w/VES Good Better Best
Premium
2-Cycle
Premium Gold
2-Cycle
VES II
2-Cycle
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.
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.
62
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 4I (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.
63
OPERATION
Fuel Valve
Turn the fuel valve clockwise
to OFF to shut off the fuel
supply. Turn the valve
counter-clockwise to ON to
turn the fuel supply on.
Fuel
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• 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.
• Turn the fuel valve off whenever the snowmobile is stored or parked.
OFF
ON
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.
64
OPERATION
Fuel
Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal
of variability in the quality of the 87 octane gasoline available
across the country, so we encourage the use of premium fuel when
possible. Always use the premium fuel switch when using premium
.
fuel
NOTE: Some engines require premium fuel. See your Owner’s Man-
Premium Fuel Switch
If your Polaris snowmobile is equipped
with a key function to adjust the timing
on the machine as you change fuels, it's
very important to the life of your
engine that you use this feature.
When using fuels with a pump-posted
octane rating of 91 or higher, turn the
key switch to ON/PREM. When the
engine is started, a yellow Premium
Fuel light illuminates on the instrument
panel. When the key is in this position,
the fuel must be a minimum of 91
octane. Return the key switch to the
ON/REG position when not using premium fuel.
ual Supplement.
OFF
ON/
PREM
ON/REG
Premium Fuel Setting
OFF
ON/
PREM
ON/REG
Regular Fuel Setting
If you're uncertain about the quality or
octane rating of the fuel you use, turn your key switch to ON/REG. The
Premium Fuel light will go out. This setting will adjust the timing of
your engine to run on fuels with 87 octane or higher. Polaris does not
recommend using fuel with lower than 87 octane. Running your
machine on ON/REG will help protect your engine from damage caused
by low octane fuels.
CAUTION
Using fuels with a lower than recommended octane or operating with
obstructed fuel systems will result in serious and costly engine damage.
Always use the recommended fuels for your machine.
65
OPERATION
Fuel
Fuel Reserve Capacity (Mechanical Gauge)
There are approximately two gallons of fuel left in the tank when the
mechanical fuel gauge reads RES.
Fuel System Deicers
If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or additives
containing methanol. Polaris also recommends the use of Carbon Clean
Plus. See page 134 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.
CAUTION
Prolonged exposure to petroleum based products may damage paint.
Always protect painted surfaces when handling fuel.
66
OPERATION
Oil
n Low Oil Indicator Light
The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile.
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.
n Low Oil Level
Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage. This is
especially important when the machine is operated in mountainous terrain.
Always check the oil level when refueling. Maintain the oil level above
the tank's low level line. When the oil reaches the low level mark, add
one U.S. quart of recommended oil. See page 62 for oil recommendations.
NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil
flow. See your Polaris dealer for recommended replacement
parts.
67
OPERATION
Carburetion
Proper carburetor adjustment is critical. A lean mixture (too much air,
too little fuel) may result in piston burning, bearing failure, or complete
engine failure. A rich mixture (too much fuel, too little air) may foul
plugs and cause generally poor engine performance.
A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may
be caused by snow build-up on the pre-filter in the air intake system.
Either condition may be caused by improper carburetor adjustment.
WARNING
Improper carburetor adjustments may result in operator safety hazards as
well as serious engine damage. Always have your Polaris dealer perform
any carburetor adjustments.
68
OPERATION
Carburetion
Jetting Guidelines
Changes in altitude and temperature affect air density, which is the
amount of oxygen available for combustion. In low elevations and cold
temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.
The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and
ambient temperatures between -10 to +10 degrees F. (-23 to -12 degrees
C). Carburetors must be re-calibrated if the snowmobile is operated outside this production temperature and/or altitude range. The main jet
installed in production is not correct for all altitudes and/or temperatures. See page 95 for more information.
CAUTION
A main jet that's too small will cause a lean operating condition and may
cause serious engine damage. Jet the carburetors carefully for elevation and
temperature according to the jetting charts in your Owner's Manual Supplement.
NOTE: It's the owner's responsibility to ensure that the correct jets are
installed in the machine for a geographical area. Be very careful when jetting down in warm weather. As the weather turns
colder it will be necessary to re-jet upward to prevent engine
damage. When selecting the proper main jet always use the
lowest elevation and temperature that is likely to be encountered.
69
OPERATION
n Engine Stop Switch
Push down on the engine
stop switch (✪) 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 carburetor/throttle system malfunction,
immediately push down the engine stop switch. Do not start the engine
again until the malfunction has been corrected by your dealer.
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.
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
70
OPERATION
Throttle Lever
WARNING
An improperly functioning throttle lever may cause erratic machine behavior
and loss of control, which could result in serious injury or death. If the throttle
lever does not work properly, DO NOT start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and carburetor 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.
71
OPERATION
Passenger Seat
The passenger seat features an adjustable
lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob.
The passenger seat and trunk cover are
removable. Removing the cover and seat
will provide open storage for transporting
larger items.
Adjustment
Knob
1. Remove the trunk
cover.
2. Push down on the seat
Latch
Lever
Tru nk
Cover
latch lever at the lower
rear of the passenger
seat.
3. Lift up the seat and
remove it from the
chassis.
4. Reverse the procedure
to reinstall the seat and trunk cover.
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 70 for more information about the
engine stop switch and throttle safety switch.
SYSTEM WHAT IT DOES
Ignition Switch Interrupts ignition circuit All
Brake Slows jackshaft All
Choke Floods engine Half throttle or less
Engine Stop Switch Interrupts ignition circuit All
Throttle Safety Switch Interrupts ignition circuit All
Tether Switch (Option) Interrupts ignition circuit All
THROTTLE
CONDITION
72
OPERATION
Emergency Starting
Your machine is equipped with a tool kit containing essential tools for
emergency use. Snowmobiles equipped with electric start have a recoil
for emergency starting. On non-electric-start models, if the recoil starter
system fails, an emergency start strap is provided in the kit.
1. Open the hood.
2. Open the clutch guard.
3. Push on the inner sheave of
the clutch and rotate clockwise slightly to relieve belt
tension.
4. 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.
5. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine. Repeat until the engine starts.
6. Close the clutch guard.
7. Close and secure the hood.
73
OPERATION
Reverse Operation
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.
• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.
• Look behind the vehicle before and while backing.
• Avoid sharp turns.
• Apply throttle slowly.
Mechanical Reverse
Make sure the shift lever is shifted completely into forward or reverse
position. Some models are equipped with a reverse indicator light that
will help you make that determination.
Do not force the shift lever into reverse if resistance is felt. The gears
may not always be aligned for shifting into reverse, and forcing the lever
may cause damage. If resistance is felt, gently apply the throttle to
move the gears to a different position and try to shift again.
The transmission may not always be in the gear indicated by the shift
lever. Apply the throttle slowly until you're sure which gear is engaged.
Sometimes the drive belt will drag in the drive clutch, causing slight
tension in the transmission and making it hard to shift. Shutting the
engine off will remove this tension and ease shifting. This should only
happen during the break-in of a new belt or when the drive/driven clutch
center distance is too long. If this is the case, belt tension adjustments
should be made by your dealer.
74
OPERATION
Reverse Operation
Electronic Reverse (PERCt)
Electronic reverse will activate only if the engine RPM is below 4000. If
your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described on page 76. Always make sure the vehicle is
stopped and the engine is running at idle before shifting to reverse.
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.
✪
75
OPERATION
Reverse Operation
Electronic Reverse (PERCt)
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 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.
Altitude Setting
At higher altitudes (above 6000 feet), the engine will require a different
ignition setting to improve the success of the reverse system. To set for
a higher altitude, start the engine and hold the button down until the
light on the instrument panel flashes rapidly, then release the button.
To set the reverse for lower elevations, continue holding the button
down until the reverse indicator light blinks slowly. Once set, it's stored
in memory until changed, whether the machine is running or not.
76
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 4I (10 cm) off the
ground.
Remove the key and cover the machine.
To w i n g
For your safety, do not attempt to use a tow hitch until you've read the
following warnings and understand the proper hitch functions.
WARNING
Objects towed with a rope have no braking power and can easily collide with
the rear of the snowmobile or other objects, resulting in serious injury or
death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a
rope. Only a stiff metal pole connecting the towed object and the tow hitch
on the snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to
prevent any possibility of contact between the snowmobile's track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn't
possible to use a rigid tow bar, attach the tow rope to the ski spindles
(not to the ski loops) to prevent damage to the steering components.
Remove the drive belt before towing, and have 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.
77
MAINTENANCE
Emission Control Information
(340cc and 600cc Engines Only)
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. The emission control system designation
per SAE J1930 is EM. If your snowmobile is equipped with a check
engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for
engine tune-ups are located in the Service Manual, which is available to
your qualified service technician. Reverse (if equipped) must not be
engaged during engine tune-ups.
78
MAINTENANCE
Emission Control Information
(340cc and 600cc Engines Only)
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty on
page 150, and read the maintenance section of your owner's manual.
You are responsible for ensuring that the specified maintenance is performed, including the emission-related maintenance outlined in these
sections of the manual.
You must inspect the air intake system on your snowmobile prior to
each use (including the airbox foam filter and hood foam filters) and
clean these components as necessary. Polaris considers the specified
maintenance for the spark plugs, oil changes, air intake system and
exhaust valves to be critical emission-related maintenance. The specified maintenance for the fuel filter is recommended additional emissionrelated maintenance. Any qualified repair shop or qualified person may
maintain, replace, or repair the emission control devices or systems on
your snowmobile. Polaris recommends that you contact an authorized
Polaris dealer to perform any service that may be necessary.
79
MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 152.
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.
80
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.
Item See
Clutch Alignment Offset
(without belt)
Drive Belt Condition 111 II II
Clutches (disassemble) 109 CC C
Belt Tension -- II II
Clutch Sheaves 109 II II
Engine Mounts -- II II
Recoil Rope -- II II
Engine Mounting Plate -- II I
Engine Torque Stop 115 II II
Cylinder Head Bolts -- II I
Cylinder Base Nuts -- II I I
Ignition Timing BTDC -- II I
VES System -- CCC I
Coolant Level 99 IIRI
Water Pump Drive Belt 111 II I
Coolant Hose -- II II
Heat Exchangers -- II I II
Coolant Circulation -- II I
Coolant Leaks -- IIII
Spark Plug Condition 91 II I RI
Exhaust Pipe 97 II
Exhaust Retaining
Springs
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
Page
150 mi.
(240 km)
110 II I
ENGINE/COOLING
97 IIII
(800 km)
CLUTCH
500 mi.
Frequency
1000 mi.
(1600 km)
2000 mi.
(3200 km)
Pre-
Season
81
MAINTENANCE
Periodic Maintenance Interval Table
Item See
Hose Routing -- II II
Hose Condition -- IIII
Fluid Leaks -- IIII
Brake Pads 103 II II
Brake Disc -- II II
Parking Brakes 56 II II
Brake System 55,
Brake Fluid 104 R
Pilot Air Screws -- II I
Carburetor
(synchronize)
Idle RPM -- III
Throttle Lever 71 II I I I
Oil Pump Lever
(synchronize)
Throttle Cable 88 LL L
Choke Cable 88 LL L
Choke 88 II I
Vent Lines -- II II
Throttle Position
Sensor
Fuel Lines 94 II I I I
Fuel Filter 94 RR
Oil Filter 94 RR
Oil Lines -- III
Oil Change -- RR
Air Box -- III II
Drain and Water Traps 96 II I
Auxiliary Shut-Off
Switch
Throttle Safety Switch 70 II I I I
Ignition Switch -- II I I I
Taillight 59 II I II
Brakelight 59 II I I I
Headlight 59 II I I I
Page
150 mi.
(240 km)
103
FUEL MANAGEMENT
95 II I
-- II I
-- II I
ELECTRICAL
59 II I II
(800 km)
BRAKES
500 mi.
Frequency
1000 mi.
(1600 km)
2000 mi.
(3200 km)
Pre-
Season
I
82
MAINTENANCE
Periodic Maintenance Interval Table
Item See
Ski Toe Alignment -- II I
Suspension Mounting
Bolts
Steering Fasteners -- II I IC
Rear Suspension Fasteners
Suspension Shock Oil -- IIII
Cooling Fins and
Shroud
Drive Shaft Bearing 87 LLL I
Jackshaft Bearings 127 LL L I
Skags (Wear Bars) 123 II I II
Ski Saddle/Spindle
Bolts
Ski Pivots 84 LLL L I
Ski Spindle 84 LLL L I
Steering Arm(s) -- I
Upper / Lower Steering
Post Support Bracket
Drive Chain Tension 102 II I II
Hood Latches 58 II I I I
Battery Fluid Level 130 II I I I
Rear Wheel Idler Bolts 119 II I I I
Idler Bolt Jam Nut 119 II I I I
Rear Suspension Pivot
Shafts
Camber Alignment -- II I
Radius Rod Bushings -- I
Handlebar Centering -- I
Tether Switch and Strap 59 II I II
Track Alignment 120 II I I I
Track Tension 118 II I I I
Front Limiter Strap -- II I I I
Rail Slide Condition 124 I
Chaincase Oil 90 II IRI
Gearcase Oil 89 II IRI
Page
150 mi.
(240 km)
-- II I II
-- II I II
-- II II
-- II I II
84 LL L L I
84 LL L
500 mi.
(800 km)
CHASSIS
Frequency
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
83
MAINTENANCE
Lubrication
Suspension and Steering
Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every
1000 miles (1600 km) thereafter. A grease gun kit, complete with grease
and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 134 for the part numbers of Polaris products.
The illustration shows the lubrication points of suspension and steering
components. Grease the left and right spindles. Raise the front end of
the machine to permit better grease entry into the spindle area.
• Lubricate both of the front ski pivots at the fittings as shown.
• Grease the jackshaft and driveshaft clutch side bearings.
• Use an aerosol lubricant on the steering post support bracket.
• Grease the steering post lower pivot.
• Grease the rear suspension pivot shafts (raise the rear of unit).
✪
✪
✪
✪
✪
84
✪
✪
✪
✪
✪
✪
✪
MAINTENANCE
Lubrication
EDGE 136 Rear Suspension (Indy 340 Touring)
✪
✪
✪
✪
Edge Touring Rear Suspension
✪
✪
✪
✪
85
MAINTENANCE
Lubrication
WideTrak Rear Suspensions
✪
✪
✪
✪
✪
86
Lubrication
MAINTENANCE
Jackshaft Bearing
Loosen the driven clutch retaining
bolt and pull the clutch outward to
expose the bearing and grease fitting. Inject grease into the grease
fitting in the flangette until grease
purges from inside or outside the
bearing seal (may take only two
pumps). Push the clutch back onto
the shaft and replace the clutch
retaining bolt. Torque to 18 ft. lbs.
(24.4 Nm).
Driveshaft Bearing
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.
Coupler Greasing
(WideTrak)
✪
✪
✪
✪
Grease the couplers on
the driveshaft and jackshaft.
Jackshaft
Driveshaft
✪
Transmission
87
MAINTENANCE
Lubrication
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.
✪
Choke and Choke Cable
Lubricate the choke slide and cables
lightly with oil or grease. Before
turning the engine off, operate the
choke intermittently to draw moisture out of the choke plunger area
and reduce the possibility of the
choke becoming frozen.
✪
88
Lubrication
n Gearcase Oil Level (WideTrak)
Check the gearcase oil level at
the intervals outlined in the
maintenance charts beginning
on page 80. Change the gearcase oil after the first 500 miles
(800 km), then every 1000 miles
(1600 km) or seasonally.
To check the oil level, place the
machine on a level surface. The
oil level should be between the
“safe” marks on the dipstick (1).
See your Polaris dealer for the
recommended oil for your
machine. Do not overfill.
NOTE: Clean the magnetic
plug (2) every 500
miles (800 km) and
whenever checking or
changing lubricant.
2
CAUTION
MAINTENANCE
1
Mixing brands or using non-recommended lubricants could result in excessive wear to chain, sprockets and bearings. Always use Polaris-recommended products for your vehicle.
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MAINTENANCE
Lubrication
n Chaincase Oil
Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 80. Change the chaincase oil after the
first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.
Maintain the oil level between the “safe” marks on the dipstick. Clean
the magnetic plug on the dipstick whenever checking or changing oil.
Polaris recommends the use of Polaris Synthetic Chaincase Lube. See
page 134 for the part numbers of Polaris products.
Oil Check
1. Position the vehicle on
a level surface.
2. Remove the dipstick (1)
and view the oil level
on the dipstick.
3. Add the recommended
oil as needed. Do not
overfill.
4. Clean the magnetic
plug (2).
5. Reinstall the dipstick.
2
1
90
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. Refer to your
Owner's Manual Supplement for the specific spark plug to be used in
your machine.
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. See your
Owner’s Manual Supplement.
• Use recommended spark plugs with the proper gap.
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
NOTE: Incorrect fuel mixture can often cause a spark plug to appear
too dark or too light in color. Before changing spark plug heat
ranges, be sure the correct main jet is installed in the carburetor(s). Refer to the Owner's Manual Supplement or see your
dealer.
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MAINTENANCE
General Maintenance
Spark Plugs
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
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, use
of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in
overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body adjustments.
the tool pouch, rotate the spark plug
counterclockwise to remove.
3. Reverse the procedure for spark plug
installation.
4. Torque the spark plug to specification.
5. Reinstall the spark plug cap.
92
MAINTENANCE
General Maintenance
Intake Filters
CAUTION
Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction.
Always reinstall the intake filters before operating the snowmobile.
The intake foam filter (✪) limits snow ingestion into the intake system.
When operating in loose powder snow, check the top of the foam filter
periodically to remove any accumulation of snow.
NOTE: These illustrations are general representations. Your model
may differ.
✪
✪
✪
93
MAINTENANCE
General Maintenance
Fuel Filter/Fuel Lines
See your Polaris dealer for replacement of the in-tank fuel filter every
1000 miles (or annually).
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.
Oil Filter
The oil filter should be changed
annually or every 1000 miles (1600
km). Inspect oil line condition at
1000 miles (1600 km). Polaris oil
filters are specially designed for use
on Polaris products. We strongly
recommend the use of only Polaris
replacement parts. See page 62 for oil recommendations.
EDGE models use an oil filter that's built into the oil sending unit
located in the bottom of the oil tank. After changing the oil filter, bleed
the oil injection system of all trapped air. See your dealer for instructions, or have your dealer perform the filter change and bleeding operation for you.
NOTE: The direction of the arrow indicates the direction of flow through
the filters.
94
MAINTENANCE
General Maintenance
Carburetor
The number stamped in the end of the main jet indicates the jet size.
The jet installed at the time of manufacture is not necessarily correct for
your elevation. It's your dealer's responsibility to make sure the correct
main jet is installed.
CAUTION
Operating the snowmobile with incorrect jetting can result in serious engine
damage. Have your Polaris dealer perform all carburetor adjustments to
ensure all adjustments are done correctly.
Carburetor Adjustments
The frequency at which the carburetors are synchronized or balanced is
important. Properly adjusted carburetors can greatly improve engine
performance, fuel economy, engine life, and reliability.
If you notice any of the following conditions, the carburetor may need
adjustment:
• Hard starting
• Poor idle
• Overheated pistons and cylinder walls
• Plug fouling
• Poor engine response to various throttle valve openings
95
MAINTENANCE
General Maintenance
Water/Sediment Trap Service
Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting
of a hose with a plug, should be drained at least every 2000 miles (3200
km) and inspected for contamination.
WARNING
When draining the traps, fuel spillage will occur. Always work in a well ventilated area away from anything that may cause the fuel to ignite, such as open
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline
warnings found on page 64.
1. Turn the fuel tank supply valve off.
2. Position a container or shop towels to
catch the contaminated gasoline.
3. Slide the clamp (1) away from the drain
plug (2) and remove the drain plug
from the sediment tube.
4. Wipe residue from the plug and reinstall it. Reposition and tighten the
clamps. Continue until all traps have
been emptied.
1
2
96
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.
Variable Exhaust System (VES)
Maintenance of the VES is limited to a periodic inspection and cleaning
of system components. Every 1000 to 2000 miles (800-1600 km), bring
the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned.
NOTE: To ensure maximum performance and minimize required main-
tenance, follow the oil recommendation chart on page 62. The
use of other lubricants may cause improper function of the
valve mechanism and increase the frequency of required
cleaning due to excessive build-up of carbon deposits.
97
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