Pantone 426C
Trail RMK
Snowmobile Owner's Manual
for Maintenance and Safety
Pantone 426C
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9922282 Rev 01
Printed in USA
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.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. 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 recre-
ational 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 2009 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.
2010 Trail RMK Owner’s Manual
P/N 9922282
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features and Controls . . . . . . . . . . . . . . . . . . . 26
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 29
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 43
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 109
Suspension Troubleshooting . . . . . . . . . . . . 110
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 111
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 124
Record maintenance and service in the log for your reference and for
future owners of the vehicle.
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3
4
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is
sold.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
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.
Some of the illustrations and photos used in this manual are general representations. Your model may differ.
5
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection
of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE standards.
Our muffler systems are designed to reduce noise levels and must not be
altered or removed. The sound of your snowmobile may not be welcome
to non-snowmobilers, so you have a responsibility to operate your
snowmobile with concern for others. We do our part by manufacturing
quieter machines; we ask your help to further reduce the impact of noise
by operating your snowmobile safely and responsibly.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction
of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
6
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: ____________________________________________________________
7
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, indicates the potential
for serious injury.
WARNING
A WARNING indicates a potential hazard that may result in serious injury or
death.
CAUTION
A CAUTION indicates a potential hazard that may result in minor injury.
NOTICE
A NOTICE indicates a situation that may result in damage to the vehicle.
8
SAFETY
WARNING
Operator Safety
Follow the recommended maintenance program beginning on page 65
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.
Driving a snowmobile requires your full attention. DO NOT drink alcohol or use
drugs or medications before or while driving. They will reduce your alertness
and slow your reaction time. In most states and provinces, it’s prohibited by law
to drive while intoxicated or under the influence of drugs.
Polaris produces high performance snowmobiles capable of traveling at high
speeds. Extra caution must be observed to ensure operator safety. Make sure
your snowmobile is in excellent operating condition at all times. We strongly recommend that the operator check major and vital safety components before
every ride.
All Polaris snowmobiles are designed and tested to provide safe operation when
used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO
NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard
and lead to bodily injury.
The warranty on your entire machine is terminated if any equipment has
been added, or any modifications have been made, to increase the speed or
power of the snowmobile.
9
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.
10
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 • Tool Kit
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under many conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING! Improper riding position may reduce control and could result in
serious injury or death. Always ride in a position that allows for control of your
vehicle.
11
SAFETY
E
4
051039
0006.31
Operator Safety
Riding Apparel
Be prepared, be warm and be
comfortable when riding. Be
aware of the weather forecast,
especially the windchill, and dress
accordingly. See the chart on page
22.
WARNING! Avoid wearing loose
clothing or long scarves, which can
become entangled in moving parts
and cause serious injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
Polaris vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and
Oceania bear the ECE 22.05 label. The
ECE mark consists of a circle surrounding
the letter E, followed by the distinguishing
number of the country which has granted
approval. The approval number and serial
number will also be displayed on the label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a
shatterproof helmet face shield. Polaris recommends wearing approved
Personal Protective Equipment (PPE) bearing markings such as VESC
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
12
SAFETY
Operator Safety
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.
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.
Excessive Speed
Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) 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.
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.
13
SAFETY
RR
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you’re snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or highways. Steep embankments may also hide
your view. Always leave yourself a way
out.
Variances in snow depth and/or water currents may result in uneven ice
thickness. Always check with local residents or authorities for general
information on conditions when traveling on lakes and streams that are
strange to you. Before riding your machine on a frozen body of water,
be sure the ice is thick enough to support the machine and its operator,
as well as the force created by a moving vehicle. You may drown if you
and the snowmobile break through the ice.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
14
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 the American
and Canadian online avalanche centers at www.avalanche.org.
15
SAFETY
Operator Safety
Ice and Snow Build-up
Before driving, manually turn the skis to the left and right to be sure ice
and snow are not interfering with full left and right steering. If difficulty
is encountered, check for ice and snow build-up that may be obstructing
the steering linkage. Snow screens and bib kits are available through
your dealer to help reduce snow and ice build-up.
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.
Driving on Slippery Surfaces
WARNING! Driving on ice or hard-packed snow reduces steering and braking
control, which may result in serious injury or death. Slow down and use caution.
If driving on ice or other slippery surfaces is unavoidable, use extreme
caution and operate at speeds no faster than a walk. Never attempt an
abrupt change of direction. The chance of “spin-out” increases under
these conditions.
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.
Operating in hilly terrain requires extreme caution to maintain balance
and avoid roll-over. If climbing a hill is unavoidable, keep all your
weight low and forward.
If you must cross the face of a slope, keep your weight on the uphill side
of the machine to maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops, or other people or vehicles that may be on the
other side of the hill.
If you’re unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn’t possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine and
set the parking brake (if equipped). Keeping away from the downhill
side of the machine, pull the rear of the snowmobile around and point
the front end and skis downhill. Remount the machine, restart the
engine, release the parking brake, and descend the hill carefully.
17
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.
Clutch Guard
Do not operate the engine with the clutch guard removed.
The clutch guard is designed to protect the operator from metal parts if
the clutch should fail. Although the chance of failure is extremely
remote, don’t defeat the purpose of the guard by removing it. It’s provided for your safety.
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may result
in personal injury or damage to the engine.
18
SAFETY
Operator Safety
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from
ice and snow before attempting to drive. Apply the throttle with enough
authority to put the machine into motion, but always operate within
safety limits. See Starting the Engine on page 49.
Maneuverability
Control and maneuverability comes not only through the steering and
skis, maximum control is achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to
carry a load.
19
SAFETY
Operator Safety
Inadequate Snow Conditions
Since snow provides the only lubrication for the power slide suspension
and, on liquid cooled models, cooling for the engine, adequate snow
cover is a requirement for operation of your machine.
NOTICE: Driving in too little snow will result in excessive wear and damage to
Operating in Deep Snow
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.
the slide rail, track and/or engine. Do not drive for prolonged periods
on blacktop, gravel, or ice. If frequently operating in low cooling conditions, see your dealer for an optional wheel kit that will reduce the
wear from overheating.
20
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 to 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 over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. 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.
21
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
WIND CHILL CHART (°F)
Wind
Speed
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.
WIND CHILL 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 -4 -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 >>
22
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
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 this guard open.
Never run engine with drive belt removed.
Never service clutches yourself - see your dealer.
Air Box Warning
This warning decal is found under the hood on applicable models:
CAUTION
Do not operate above 40 mph with hood-to-air box foam removed
or engine failure will result.
Passenger Warning
Your Polaris snowmobile is
designed for a single rider only.
A decal on the console indicates
single rider operation:
WARNING
This vehicle is designed for
operator only.
NO PASSENGER.
23
SAFETY
+
+
Safety Decals and Locations
Track/Seat Warning
The track/seat warning decal is on the
rear of the tunnel:
WARNING
Stay clear of track. Do not sit on seat
back. Entanglement with the track or
a fall from seat back may result in
severe injury or death.
Reverse Warning
Polaris snowmobiles equipped with
electric reverse and will have this
decal on the console:
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.
NOTE: 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.
24
SAFETY
Safety Decals and Locations
Operation Warning
An operation warning decal is present on the console of all Polaris
snowmobiles:
WARNING
• 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 the engine, check throttle, brake, and steering for
proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when
refueling.
25
FEATURES AND CONTROLS
5
4
3
2
1
10
9
7
8
6
1. Fuel Filler Cap (may include a fuel gauge)
2. Ignition Switch
3. Brake Lever
4. Speedometer (may include indicator/warning lights)
5. Reverse Indicator
6. Mountain Bar (accessory)
7. Engine Stop Switch (see page 58)
8. Throttle Control
9. Choke
10. Recoil Starter Handle
26
FEATURES AND CONTROLS
2
5
4
3
1
ONOFF
Some Polaris snowmobiles are equipped with special features. Controls
for these features are illustrated on this page. Not all models come with
these features. See your Owner’s Manual Supplement.
Tip: Accessories are available from your Polaris dealer.
1. Headlight Dimmer
Switch
2. Parking Brake
Lock
3. Handlebar Grip
Warmer Switch
4. Thumbwarmer
Switch
5. Electronic Reverse
Button
Fuel Valve
The fuel valve is located under the
hood. Turn the fuel valve off whenever the snowmobile is stored or
parked.
1. Turn the valve clockwise to
turn off the fuel supply.
2. Turn the valve counter-clock-
wise to turn on the fuel supply.
27
FEATURES AND CONTROLS
13
1
2
3
4
5
6
7
8
10
9
11
14
12
1. Hood
2. Headlight
3. Windshield
4. Handlebar
5. Operator Seat
6. Storage Compartment
7. Taillights
8. Snow Flap
9. Track
10. Suspension
11. Trailing Arm
12. Nosepan
13. Front Bumper (do not use for pulling or dragging the snowmobile)
14. Skis
28
THE PERFECT FIT
1
2
3
4
Front Suspension Adjustments
Break in the suspension for approximately 150 miles (240 km) and regrease all suspension parts before making any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail conditions. We recommend starting with
factory settings and then customizing each adjustment individually to
suit rider preference. The machine should be methodically tested under
the same conditions after each adjustment (trail and snow conditions,
vehicle speed, riding position, etc.) until the best ride is achieved.
Adjustments should be made to one area at a time in order to properly
evaluate the change.
IFS Components
1. Skis
2. Front shocks and springs
3. Rod ends
4. Trailing arms
IFS Adjustment Options
• Front shock spring preload
• Optional springs
29
THE PERFECT FIT
1
3
4
5
2
Front Suspension Adjustments
WARNING! Improper ski alignment or adjustment may cause loss of steering
control, resulting in serious injury or death. Always verify ski alignment before
making adjustments to the IFS. See page 98 to check alignment. Do not attempt
to change the ski alignment or camber adjustment. See your Polaris dealer.
The tension at which the shock coil spring is set is called spring preload.
For the best ride, the spring preload should be set as low as possible to
use the full travel of the ski shock, with occasional light bottoming. To
determine if your machine is using full travel of the ski shock, push the
jounce bumper down as far as it will go on the shock rod and test ride
the machine. The bumper will move up on the rod in direct relation to
the amount of travel. If the shock travel is full, the bumper will be seated
at the top of the shock.
Shock Components
1. Retainer
2. Shock Rod
3. Jounce Bumper
4. Body
5. Threaded Spring Preload
Adjuster Nut
30
THE PERFECT FIT
Front Suspension Adjustments
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.
31
THE PERFECT FIT
Low
Preload
High
Preload
Front Suspension Adjustments
Shock Spring Preload
Increasing spring preload will
increase ski-to-ground pressure.
Decreasing spring preload will
decrease ski-to-ground pressure.
When adjusting, be sure the springs
on both the left and right sides of the
machine are at the same adjustment.
To increase front shock spring preload, grasp the spring and turn it to
the right. Turn it to the left to decrease
preload.
Increasing the spring preload too
much may adversely affect the handling of the snowmobile and the performance of the suspension. Never
exceed one inch of preload beyond
the factory settings, and ensure that
both sides are adjusted the same.
When decreasing preload, make sure
at least two turns of preload are holding the spring between the retainer
on top of the shock and the threaded spring preload adjuster nut on the
shock body.
Tip: Some models do not have shocks with thread adjustable spring preload.
See your dealer for more information.
NOTICE: 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.
32
THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action. Each rear suspension can be adjusted to suit rider
preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross
racing would provide a very stiff ride on the trail. A suspension set up
for trail riding would bottom out harshly on a snow-cross course.
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.
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 set-up. 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 a
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.
Tip: 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 71.
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 94.
33
THE PERFECT FIT
X
Y
Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the EDGE RMK rear suspension torsion spring preload, measure the distance between the ground and rear bumper (see illustration).
This measurement should be taken with no rider and the rear suspension
at full extension. This is measurement X.
Take the first measurement with no rider and with the rear suspension at
full extension.
Tip: 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.
34
THE PERFECT FIT
Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method))
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 this 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.
35
THE PERFECT FIT
Soft/Low Tension
(Long end to front)
Medium Tension
(Short end up)
High/Firm Tension
(Long end up)
High
Low
Rear Suspension Adjustments
Torsion Spring Preload
To adjust rear torsion
spring preload, 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.
Optional Torsion Springs
Track Soft Standard Firm
136 Not applicable 7041627-067 7041628-067
.347 77
Limiter Strap Position
The following information is provided only as a guideline to be
used for initial suspension set-up.
Your set-up may vary based on
your desired riding style.
High: Limiter strap in high posi-
increases ski pressure
tion
Low: Limiter strap in low position
decreases ski pressure
ο
7041629-067 7041630-067
.359 77
ο
36
THE PERFECT FIT
Adjustment Screw
Rear Suspension Adjustments
Shock Compression Damping
Your snowmobile is equipped with the Indy Select rear shock, which
allows for adjustments to the compression valving.
1. Locate the adjustment screw near the base of the shock.
2. Adjust the screw 1/2 turn clockwise to increase compression valv-
ing and stiffen the ride. Test ride the snowmobile before making
further adjustments.
Tip: An excessive adjustment can result in damage to the shock. When adjust-
ing these shocks, we recommend that you turn the screw only 1/2 turn at a
time, then test ride.
3. Adjust the screw 1/2 turn 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 36). Return the screw to its
original starting position after the torsion spring has been tightened.
37
THE PERFECT FIT
Cover
Nuts
Bolts
Handlebar Adjustments
Standard Handlebar
Follow these steps to adjust handlebar angle at the handlebar block.
1. Remove the handlebar cover
to expose the handlebar and
the four adjuster block bolts.
2. Using a 7/16-inch wrench,
loosen the four nuts on the
bottom of the adjuster block
(turn the handlebar either left
or right for access to the rear
nuts). If necessary, pry the
blocks apart with a screwdriver.
3. Adjust the handlebar to the
desired angle. Be sure the
handlebar, brake lever and
throttle lever operate
smoothly and do not hit the
gas tank, windshield or any
other part of the machine
when the handlebar is turned
fully to the left or right.
4. Torque the front bolts first, then torque the rear bolts. Torque the
bolts to 11-13 ft. lbs. (15-18 Nm).
5. Reinstall the handlebar cover.
38
THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile. From
map light to electric start, Polaris has the accessories that will help make
each ride more enjoyable. See your dealer for a list of accessories.
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
• Personal injury to self or others
This applies to, but is not limited to the following areas: brakes,
clutches, fuel systems, and exhaust systems.
Tip: Exhaust systems are critical safety areas that must use approved Polaris
parts. Please see your Polaris dealer for service.
39
THE PERFECT FIT
Traction Products
Another way to tailor your machine is to install traction products. See
your dealer about installing studs and/or carbides. Many tracks with
deep lug designs cannot be studded, but your dealer will be able to offer
advice and assistance.
NOTICE: Installing studs on models without wear strips will result in damage to
Tip: Before equipping your machine with traction products, be aware of the laws
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.
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.
NOTICE: Use of studs longer than the recommended length on machines
the cooler or tunnel. Always ensure that wear strips are installed
before installing studs. See your dealer for more details.
in your area pertaining to the use of traction products.
equipped with coolers will result in damage to the cooler or tunnel.
Always use the recommended length studs.
40
THE PERFECT FIT
Traction Products
A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering
and control. Similarly, if your machine is equipped with carbide skags
or if you’re adding them, it may be necessary to add track studs to maintain proper vehicle control. Proper balance must be maintained between
the number of studs and the length of the carbide on skags. The more
studs used, the longer the carbide on the skags should be. See your
dealer’s track studding chart for recommended studding and skags.
n Inspect skags and studs frequently. Worn studs or skags may reduce
steering and braking control on hard-packed snow and ice. Replace
worn studs and skags to maintain proper balance and vehicle control.
See page 99.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are available. See your dealer for more information.
NOTICE: Aggressive studding patterns may require that you grind protruding
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.
stud bolts flush to prevent idler wheel damage. Maintain track tension
on studded tracks on the tight side of the spec to prevent heat
exchanger damage. Center of stud must be at least 1 1/8 inches (2.86
cm) from the outside edge of the track.
41
THE PERFECT FIT
1
2
4
3
Traction Products
Wear Strips
To avoid excessive tunnel or cooler damage, wear strips must be
installed whenever track studding is used. See your dealer for more
information.
Wear strips are designed for a specific stud length. See your dealer’s
studding chart for recommended traction accessories.
NOTICE: Never add shims to the wear strip. Track damage will result due to
Components as viewed from the rear of the track:
1. Top of tunnel
2. Wear strip
3. Track
4. Wear strip mounting holes
lack of clearance between upper carrier wheels and track.
NOTICE: Whenever wear strips are relocated, be sure there’s adequate stud
42
clearance to the heat exchangers. Lack of clearance may result in
damage to heat exchangers.
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (
locate the pre-ride inspection items
Item See Page
Drive Belt Condition 87, 90
Steering System 47
Recoil Rope 47
Parking Brake Lock/Brake Lever/Brake System 45, 46, 81
Auxiliary Shut-Off Switch (Engine Stop Switch) 58
Ignition Switch 48
Taillight/Brakelight/Headlight 48
Suspension Mounting Bolts 100
Skags (Wear Bars) 41, 99
Ski Saddle and Spindle Bolts 100
Hood Straps/Latches 47
Throttle Lever/Safety Switch 44, 58, 59
Rear Wheel Idler Bolts 95, 100
Tether Switch/Strap N/A
Track Alignment/Condition 47, 96
Front Torque Arm Limiter Strap Condition --
Rail Slide Condition 100
Chaincase Oil Level 73
Injection Oil Level 55
n) on the referenced pages to
43
PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.
WARNING! Operating the vehicle with worn, damaged, or malfunctioning
components could result in serious injury or death. Never start the engine
without checking all vehicle 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. See page 59.
n Throttle Safety Switch
Test the throttle safety switch system before the machine is operated.
See page 58.
44
PRE-RIDE INSPECTIONS
1/2 inch (1.3 cm)
Before Starting the Engine
n Brakes
Properly functioning brakes are critical to your safety. Always check the
following items to assure proper operation before starting the engine.
Brake Lever Travel
Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2 inch (1.3
cm). A smaller distance indicates low brake fluid level or
air in the hydraulic system.
See pages 82-83 or see your
dealer for service.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Also check for the presence of air in the fluid system. See pages 82-83 or see your dealer for service.
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.
45
PRE-RIDE INSPECTIONS
1
2
3
4
Before Starting the Engine
n Parking Brake Lever Lock
Your snowmobile may have a
parking brake lever lock located
over the brake lever. Use the
brake lever lock only when you
want the machine to remain stationary; for example, when
parked on an incline for a period
of five minutes or less.
1. Brake Lever
2. Parking Brake Lever Lock
3. Master Cylinder Reservoir/
Cover
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze the brake lever tightly and push forward on
the lock. Hold the lock forward while releasing the brake lever.
NOTICE: If the brake lever is squeezed tightly enough, the lock will move freely
The brake light will illuminate if the parking brake lever lock is set
while the engine is running. It will also illuminate when the service
brake is in use. If the parking brake light does not come on when the
parking brake or service brake is in use, have it serviced by your dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will return
to the unlocked position.
WARNING! If the parking 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.
into place. Do not force the lock or it may break.
46
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. Make sure all greasable components are properly
lubricated.
n Track
WARNING! Always inspect the track for damage before using the vehicle.
Operating the snowmobile with a damaged track increases the possibility of
track failure, which could cause loss of control resulting in serious injury or
death.
Use of traction products such as studs increases the possibility of track
damage and/or failure. Driving at high speeds for extended periods of
time with inadequate lubrication could severely damage track rods,
break track edges, and cause other track damage. Examples of inadequate lubrication would include frozen bodies of water without snow
cover, icy trails, and no-snow conditions.
Track damage or failure caused by operation on ice or under poor lubrication conditions voids the track warranty.
n Hood Latches
The hood of the snowmobile protects the operator from moving parts as
well as aiding in sound emission control and other functions. Under no
circumstances should your snowmobile be operated with the hood open
or removed. Always ensure that the hood straps are in good condition
and that the latches are securely in place before operating the snowmobile.
n Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure the
knot securing the rope inside the handle is secure. If excessive wear is
found, see your Polaris dealer for replacement.
47
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 Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
n Mirrors (if equipped)
Adjust the mirrors so they can be used to their full advantage.
n Operating Area
Before driving, check your surroundings. Be aware of obstacles and
make sure bystanders are a safe distance from the machine.
n Ignition Switch
Make sure the engine stops when the ignition switch is turned to OFF.
48
OPERATION
CHOKE POSITIONS
OFF
1/2 CHOKE
FULL CHOKE
Starting the Engine
NOTICE: Engaging the starter when the engine is running WILL result in serious
1. Turn the fuel valve on. See
2. Turn the key to the ON
3. Pull the engine stop switch
4. If starting a cold engine,
CAUTION! Do not depress the throttle until the engine starts.
CAUTION! 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
NOTICE: Don’t pull the starter rope to the fully extended position and don’t allow
6. If not equipped with electric start, grasp starter handle and pull
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
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
page 27.
position.
up to the RUN position.
flip the choke toggle to
FULL CHOKE. Do not
use the choke if starting a
warm engine.
engine. Release the key to the ON position when the engine starts.
it to snap back into the housing. Damage may result.
slowly until the recoil engages; then pull abruptly to crank the
engine.
the engine slows or wants to stop, use intermittent choking to the
HALF CHOKE position.
49
OPERATION
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of gasoline with one pint of Polaris injection oil for each five
gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.
NOTICE: 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.
50
OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. See page 55.
NOTICE: Serious engine damage can occur without the proper lubrication.
Oil Recommendations
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of Premium 2-Cycle Oil for this
engine. See page 109 for the part numbers of Polaris products.
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.
Check the oil tank level often during the first tankful of fuel. If the oil
level doesn’t go down, contact your dealer immediately.
51
OPERATION
Track Warm-Up
WARNING! Use of traction products such as studs, ice growsers, etc. will
increase the possibility of track damage and/or failure. This could cause loss of
control, resulting in serious injury or death. Always inspect for track damage
before operating the snowmobile.
Follow these steps to ensure proper warm-up of the engine, drive train
and track.
1. Use an appropriate stand to securely
support the rear of the snowmobile at the
rear bumper. The track should be
approximately 4 inches (10 cm) off the
ground.
WARNING! A loose track or flying debris could
cause serious personal injury or death. Stand
clear of the front of the machine and the moving
track. Never hold the snowmobile up or stand
behind it while warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Be sure the
rear support is stable.
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.
Tip: It will take longer to warm up the track sufficiently during colder outdoor
temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the machine to the ground.
5. Grasp the skis by their front loops and move them from side to side.
This will loosen frozen snow from the ski bottoms, allowing the
machine to move forward more easily.
6. The engine, drive system and track are now properly warmed up
and the machine may be driven following normal safety practices.
52
OPERATION
Slide Rail and Track Cooling
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide
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 refu-
• If gasoline spills on your skin or clothing, immediately wash it off with soap
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes
• Turn the fuel valve off whenever the snowmobile is stored or parked.
Exhaust
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.
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.
eling is performed or where gasoline is stored.
and water and change clothing.
are poisonous and can cause loss of consciousness or death in a short time.
53
OPERATION
Fuel
Fuel Recommendations
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, so we encourage the
use of premium fuel when possible. Do not use lower than 87 octane
fuel. Do not use fuel containing more than 10% ethanol (including E85).
NOTICE: Using fuels with a lower than recommended octane or operating with
Fuel Reserve Capacity (Mechanical Gauge)
There are approximately two gallons of fuel left in the tank when the
mechanical fuel gauge reads RES.
Fuel System Deicers
If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 milliliters per liter) of gasoline to prevent engine damage resulting
from fuel system icing and lean fuel mixtures. Never use deicers or
additives containing methanol. See page 109 for the part numbers of
Polaris products.
If you use oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used.
NOTICE: Prolonged exposure to petroleum based products may damage paint.
obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine.
Always protect painted surfaces when handling fuel.
54
OPERATION
n Oil
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. If oil is not visible, continued operation may cause serious engine damage. Add oil before further operation
of the snowmobile. See page 51 for oil recommendations.
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. When the oil reaches the low
level mark, add one quart (.9 l) of recommended oil to the tank. See
page 51 for oil recommendations.
NOTICE: Operating the snowmobile without adequate engine lubrication can
The Polaris oil cap on the oil bottle may be vented to allow proper oil
flow. See your Polaris dealer for recommended replacement parts.
result in serious engine damage. Always check the oil level when refueling. Add oil as needed.
55
OPERATION
Carburetion
Proper carburetor adjustment is critical. Always have your Polaris
dealer perform any carburetor adjustments.
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.
56
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.
RMK carburetors are preset to operate at altitudes of 6000-8000 feet
(1800-2400 m) above sea level (see page 78 for more information). 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.
NOTICE: A main jet that’s too small will cause a lean operating condition and
Tip: It’s the owner’s responsibility to ensure that the correct jets are installed in
may cause serious engine damage. Jet the carburetors carefully for
elevation and temperature according to the jetting charts. See your
Owner’s Manual Supplement.
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.
57
OPERATION
Stop Switch
n Engine Stop Switch
Push down on the engine
stop switch to stop the
engine in an emergency.
This will ground out the
ignition and bring the
engine to a quick stop.
To restart the engine, the
switch must be pulled up
to the ON position.
n Throttle Safety Switch
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. Test the throttle
safety switch system daily before operation.
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.
58
OPERATION
n Throttle Lever
WARNING! An improperly functioning throttle lever may cause erratic machine
behavior and loss of control, which could result in serious injury or death. If the
throttle lever does not work properly, DO NOT start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and carburetor(s) 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 free play 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.
59
OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. Refer to page 58 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
WARNING! Excessive or repetitive use of brakes for high speed stops will
cause an overheated brake system. This overheated condition could cause
sudden loss of brakes and/or fire, resulting in serious injury or death. When
traveling on long downhill stretches, pump the brakes. Riding the brakes may
cause the brake system to overheat and result in brake failure.
THROTTLE
CONDITION
60
OPERATION
Electronic Reverse (PERCt)
Electronic reverse will activate only if the engine is below 4000 RPM. If
your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described on page 62. Always make sure the vehicle is
stopped and the engine is running at idle before shifting to reverse.
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.
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 transmission is in reverse.
4. Apply the throttle slowly to make sure the transmission is in
reverse.
Tip: The maximum engine RPM will be 6000 when in reverse.
Tip: If the engine stops running, the snowmobile will be in forward gear when it's
restarted.
61
OPERATION
Electronic Reverse (PERCt)
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
NOTICE: Engaging the starter when the engine is running WILL result in serious
2. Push the yellow reverse button for one second and release. The
3. Apply the throttle slowly to make sure the transmission is in for-
Ignition 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.
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
engine will slow and begin to rotate forward. The light on the
instrument panel will shut off.
ward.
62
OPERATION
Towing
Do not use the front bumper to pull or drag the snowmobile. The front
bumper is not designed for this type of use and may detach from the
vehicle if force is applied.
For your safety, do not attempt to using the tow hitch until you’ve read
the following warnings and understand the proper hitch functions.
WARNING! Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting in serious
injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle
with a rope.
Only a stiff metal pole connecting the towed object and the tow hitch on
the snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2 meters)
long to prevent any possibility of contact between the snowmobile’s
track and a person riding in the towed object.
Braking distances increase when towing loads. Slow down to maintain
control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn’t
possible to use a rigid tow bar, attach the tow rope to the ski spindles
(not to the ski loops) to prevent damage to the steering components.
Remove the drive belt before towing, and have a rider on the towed
snowmobile to operate the brake and steering when necessary.
NOTICE: 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.
63
MAINTENANCE
Emission Control Information
Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang tag. 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 hang tag,
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. 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.
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty, and
read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris
recommends that you contact an authorized Polaris dealer to perform
any service that may be necessary.
64
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 124.
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.
NOTICE: 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.
65
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 Offset Alignment
(without belt)
Drive Belt Condition 87 IIII
Clutches (disassemble) 86 CC C
Belt Tension -- II II
Clutch Sheaves 90 II II
Engine Mounts -- II II
Recoil Rope 47 II II
Engine Mounting Plate -- II I
Engine Torque Stop 91 II II
Cylinder Head Bolts -- II I
Cylinder Base Nuts -- II I I
Ignition Timing BTDC -- II I
Spark Plug Condition 74 III I I
Exhaust Pipe 80 II
Exhaust Retaining
Springs
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
Page
150 mi.
(240 km)
86 II I
80 II II
500 mi.
(800 km)
CLUTCH
ENGINE
Frequency
1000 mi.
(1600 km)
2000 mi.
(3200 km)
Pre-
Season
66
MAINTENANCE
Periodic Maintenance Interval Table
Item See
Hose Routing -- II II
Hose Condition -- II II
Fluid Leaks -- II II
Brake Pads 81 II II
Brake Disc -- II II
Parking Brakes 46 II II
Brake System 45,81 I
Brake fluid 82 R
Pilot Air Screws -- II I
Carburetor (synchronize) 56 II I
Idle RPM -- II I
Throttle Lever 44,59 II I I I
Oil Pump Lever
(synchronize)
Throttle Cable 72 LL L
Choke Cable 72 ILLL
Vent Lines -- II II
Throttle Position Sensor -- II I
Choke 72 III
Fuel Filter 79 RR
Fuel Lines 79 II I I I
Oil Filter 79 RR
Oil Lines 79 III
Oil Change N/A RRI
Air Box -- II I I I
Drain and Water Traps 77 II I
Page
150 mi.
(240 km)
FUEL MANAGEMENT
-- II I
500 mi.
(800 km)
BRAKES
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
67
MAINTENANCE
Periodic Maintenance Interval Table
Item See
Auxiliary Shut-Off Switch 48 II I I I
Throttle Safety Switch 44,58 II I I I
Ignition Switch 48 II I I I
Taillight 48 II I I I
Brakelight 48 II I I I
Headlight 48 II I I I
Ski Toe Alignment -- II I
Suspension Mounting
Bolts
Steering Fasteners -- II I IC
Rear Suspension
Fasteners
Suspension Shock Oil -- II II
Cooling Fins and Shroud -- II II
Drive Shaft Bearings 72 LL L I
Skags (Wear Bars) 99 II I I I
Ski Saddle/Spindle Bolts -- II I I I
Ski Pivots 70 LLL L I
Ski Spindle 70 LL L L I
Steering Arm(s) 70 LL L L I
Upper/ Lower Steering
Post Support Bracket
Hood Straps 47 II I I I
Battery Fluid Level 101 II I I I
Rear Wheel Idler Bolts
and Nuts
Page
150 mi.
(240 km)
ELECTRICAL
-- II I I I
-- II I I I
70 LL L L I
95 II I I I
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
68
MAINTENANCE
Periodic Maintenance Interval Table
Item See
Rear Suspension Pivot
Shafts
Camber Alignment -- II I
Radius Rod Bushings -- I
Handlebar Centering -- I
Track Alignment 96 II I I I
Track Tension 94 II I I I
Front Limiter Strap -- II I I I
Rail Slide Condition 100 I
Chaincase Oil 73 II I RI
Gearcase Oil N/A II I RI
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
Page
150 mi.
(240 km)
71 LL L
500 mi.
(800 km)
CHASSIS
Frequency
1000 mi.
(1600 km)
2000 mi.
(3200 km)
Pre-
Season
69
MAINTENANCE
+
+
+
+
+
Lubrication
Front Suspension
Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every
1000 miles (1600 km) thereafter. See page 109 for the part numbers of
Polaris products.
The illustration shows the location of suspension and steering components. A + indicates a grease point or fitting.
• 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 driveshaft clutch side bearing.
• Use an aerosol lubricant on the steering post support bracket.
• Grease the center steering arms.
• Grease the steering post lower pivot.
• Grease the rear suspension pivot shafts (raise the rear of unit).
A grease gun kit, complete with grease and adaptors, is available to
lubricate all fittings on Polaris snowmobiles. See page 109.
70
MAINTENANCE
+
+
+
+
Lubrication
Rear Suspension
The suspension pivot shafts should be lubricated with Polaris Premium
All Season Grease at 500 miles (800 km) initially, every 1000 miles
(1600 km) after that, and before off-season storage each year. Lack of
lubrication will adversely affect your ride and the life of the suspension.
For detailed information about suspension lubrication and adjustments,
see your Polaris dealer.
Tip: The following illustrations are general representations. Your model may dif-
fer. Lubrication points are indicated by a
+.
71
MAINTENANCE
+
+
+
Lubrication
Jackshaft Bearing
The jackshaft bearing on your model may be equipped with a grease fitting, but this component is greased for life at the factory. Additional
lubrication is not required.
Driveshaft Bearing
Inject grease into the fitting on the
speedometer drive adaptor until
grease purges from inside or outside
the bearing seal (approximately two
pumps).
Throttle Cable
Lubricate the throttle cable lightly
with grease or oil. With the engine
off, turn the handlebars to the left
and lubricate liberally as shown.
Choke and Cable
Lubricate the choke slide 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.
72
MAINTENANCE
Dipstick
Magnetic
Plug
Lubrication
n Chaincase Oil Level
Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 66. 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 109 for the part numbers of Polaris products.
Oil Check
1. Position the vehicle on
a level surface.
2. Remove the dipstick
and view the oil level
on the dipstick.
3. Add the recommended
oil as needed. Do not
overfill.
4. Clean the magnetic
plug.
5. Reinstall the dipstick.
73
MAINTENANCE
Spark Plugs
It’s very important to use the correct spark plug for your machine. A
spark plug with a heat range too high will cause engine damage. A spark
plug with a heat range too low will cause excessive fouling and engine
malfunctioning.
In selecting a spark plug heat range for production, a manufacturer
assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal
damage if the purchaser actually does operate the engine in this manner.
This selection could cause the customer who normally operates the
engine under medium or light duty to have spark plug failure.
NOTICE: A spark plug with a heat range too high will always cause engine dam-
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.
• Use recommended spark plugs with the proper gap. See your Owner’s
• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).
• Always carry spare spark plugs.
age 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.
Manual Supplement.
74
MAINTENANCE
Spark Plugs
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
Tip: 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). See your Owner’s Manual Supplement.
Normal Plug
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.
The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect carburetion adjustments.
Wet Fouled Plug
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. Wear protective gloves.
2. Remove the spark plug cap.
3. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
4. Reverse the procedure for spark plug installation. Torque to 18-22
ft. lbs. (24.4-29.8 Nm).
5. Reinstall the spark plug cap.
75
MAINTENANCE
Intake
Foam Filter and Screen
Foam Filter
Air Intake Box
Intake Filter
The intake foam filter and screen limits snow ingestion into the intake
system. When operating in loose powder snow, check the top of the
foam filter and screen periodically to remove any accumulation of snow.
NOTICE: Operating the snowmobile with the intake filters removed may cause
These illustrations are general representations.Your model may differ.
carburetor icing. The result will be poor fuel economy or carburetor
malfunction. Always reinstall the intake filters before operating the
snowmobile.
76
MAINTENANCE
Clamp
Drain
Plug
Carburetor
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 about every 1000 miles (1600
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 53.
Plug Cleaning Procedure
1. Turn the fuel valve off.
2. Position a container or shop towels to
catch the contaminated gasoline.
3. Slide the clamp away from the drain
plug and remove the drain plug from the
sediment tube.
4. Wipe residue from the plug and reinstall
it. Reposition and tighten the clamps.
Continue until all the traps have been
emptied.
77
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.
NOTICE: Operating the snowmobile with incorrect jetting can result in serious
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
engine damage. Have your Polaris dealer perform all carburetor
adjustments to ensure all adjustments are done correctly.
78
MAINTENANCE
Fuel Filter/Fuel Lines
The fuel filter is located inside the fuel tank. This component requires
no maintenance.
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.
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel
Oil Filter
The oil filter on your model is assembled into the oil sending unit
located in the bottom of the oil tank. This component requires no maintenance.
If service is performed to the oil injection system, trapped air must be
bled from the system. See your dealer for instructions, or have your
dealer perform this service.
lines may cause damage to the lines. If a fuel line has been damaged
or kinked, replace it promptly.
79
MAINTENANCE
Jam
Nut
Adjuster
Bolt
Exhaust System
Check the exhaust system for wear or damage at approximately 1000
miles (1600 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.
CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.
Drive Chain Tension
To obtain correct chain tension:
1. Rotate the driven clutch coun-
terclockwise to move all chain
slack to the tensioner side.
Lock the brake lever lock, or
have an assistant hold the
brake lever firmly.
2. Loosen the adjuster bolt jam
nut.
3. Finger tighten the adjuster
bolt until it can no longer be
adjusted by hand, then back
off 1/4 turn.
4. Tighten the jam nut while
holding the adjuster bolt.
5. The chain is now tensioned.
Release the brake lever lock.
80
MAINTENANCE
1
2
3
4
5
Brakes
n Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 45.
Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is
available for replacing brake pads. See your dealer.
WARNING! Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the brake pads do
not drag on the disc and that brake lever travel is not excessive. Always replace
brake pads when the brake pad material becomes thinner than the backing plate
(approximately 1/16 inch/1.5 mm).
Brake Components
1. Brake Caliper
2. Chaincase
3. Brake Disc
4. Backing Plate
5. Brake Pad Material
(Replace when thickness is
less than 1/16 inch/1.5 mm)
81
MAINTENANCE
Brakes
Brake Fluid
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or severe injury.
The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black. If
the sight glass is any color other than black, add brake fluid.
Keep the master cylinder cover free of dirt and debris. The vent slits
allow for diaphragm movement, and if they become plugged, movement
of brake fluid below the diaphragm may be restricted, altering brake
function.
We recommend the use of Polaris DOT 4 high temperature brake fluid.
See page 109 for the part numbers of Polaris products.
NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe
Replace brake fluid at least every two years.
up spills immediately.
82
MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING! Operating the vehicle with a spongy brake lever can result in loss of
brakes, which could cause an accident and lead to serious injury or death.
Never operate the vehicle with a spongy-feeling brake lever.
During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.
3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder
valve 3/4 of a turn to release air.
5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.
WARNING! Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or death. Always
add brake fluid to the fill line as recommended.
7. After bleeding is complete, refill the reservoir to the proper level.
8. Reinstall the gasket and cover.
83
MAINTENANCE
2 in. (5.1 cm)
Lamp Center Height
25 ft. (7.6 m)
Adjustment
Nut
Lights
Headlight Adjustment
The headlight may be adjusted for vertical aim using the following procedure:
1. Place the snowmobile on a level surface with the headlight approxi-
mately 25 feet (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall.
3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed two (2) inches (5.1 cm) below the mark
placed on the wall in step 4.
Tip: Rider weight must be included on the seat.
5. Turn the adjustment nut, located inside the hood, just below the
headlamp opening. Turn the knob in or out as needed for proper
aim.
84
MAINTENANCE
1
2
3
Lights
NOTICE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a
Removing Halogen Bulbs
1. Pinch the ends of the spring (1)
2. Lift spring carefully around
3. With the wire harness attached
4. Grasp bulb by metal base and
Installing Halogen Bulbs
1. Hold bulb by metal base and install into wire harness.
2. Insert bulb into housing.
3. Carefully flip spring back into housing placing it around wire har-
4. Squeeze spring together until it is over the spring retainer and
5. Verify headlight aim.
residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel.
together and lift until it releases
from the spring retainer.
wire harness (2) and flip to outside of housing.
to the bulb (3), withdraw bulb
from housing.
carefully separate bulb from
harness.
ness.
release.
85
MAINTENANCE
Clutch System
Periodically inspect the clutch sheaves for damage, wear, or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.
NOTICE: If you become aware of higher than normal clutch engagement or an
Clutch Alignment Offset
Clutch alignment offset is important for maintaining optimum performance. Please see your Polaris dealer if you experience a decrease in
performance.
Clutch Center Distance
See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.
unusual vibration or shift pattern, see your dealer immediately. Do not
operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer.
Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.
The bushings in the weights and rollers of Polaris clutches are made
of a material that may be damaged if lubricated. Do not lubricate
clutch bushings.
86
MAINTENANCE
Clutch System
n Drive Belt Condition
Belt width and length must match the center distance of the clutches and
sheave width of the drive clutch. For this reason, Polaris recommends
that only O.E.M. belts be used. Other belts may match the dimensions,
but can drastically change the shift pattern, resulting in poor performance. See Belt Troubleshooting on page 111.
Periodically check the condition and tension of the drive belt, and
always carry a spare. Inspect the belt for signs of excessive wear: frayed
edges, missing cogs, cracks and excessive looseness. Replace the belt if
any of these conditions exist.
Tip: A worn belt will continue to function, but will not deliver maximum perfor-
mance. Always carry a spare belt in case of an emergency.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.
87
MAINTENANCE
Clutch System
Drive Belt Removal
1. Stop the engine after operating in a forward motion.
NOTICE: Do not attempt to remove the drive belt after operating in reverse. The
2. Turn the ignition key off. Wait for
3. Lock the parking brake (if
4. Open the hood.
5. Remove the clutch guard retain-
6. Rotate the driven clutch counter-
7. Locate the L-wrench in the tool kit and install it into the open
8. Firmly grasp the belt midway between the clutches and pull upward
snowmobile must be stopped after forward motion to prevent damage
to components during belt removal.
the engine to stop completely.
equipped).
ing pin and open the clutch
guard.
clockwise 1/4 turn by hand to
ensure forward engagement
before attempting to remove the
belt.
threaded hole in the outer sheave of the clutch. Rotate the wrench
until the sheaves open far enough to remove the belt.
and rearward to remove. See illustration.
88
MAINTENANCE
Clutch System
Drive Belt Installation
1. Drop the drive belt over the
drive clutch and pull back
the slack.
Tip: To ensure satisfactory belt life,
install belts so they operate in
the same direction of rotation
by positioning the identification
numbers so that you can read
them. If required, separate the
sheaves as outlined in the belt
removal procedures.
2. Turn the driven clutch
moveable sheave clockwise
while pushing inward and forcing the belt down between the
sheaves.
3. Hold the belt down between
the sheaves and roll the bottom portion over the outer
clutch sheave. Work the belt
to the outer edge of the
sheave.
4. Rotate the L-wrench to
tighten the sheaves. Remove
the wrench and store in the
tool kit.
5. Close the clutch guard and
reinstall the retaining pin.
6. Close and secure the hood and release the parking brake.
89
MAINTENANCE
1
2
Clutch System
n Drive Belt Deflection
Measure belt deflection with
both clutches at rest and in
their full neutral position.
Place a straight edge on the
belt (1) and apply downward
pressure while measuring at
point 2. This measurement
should be 1 1/4 inches (32
mm).
Drive Belt Adjustment
Belt deflection should be adjusted without removing the clutch from the
jackshaft.
1. Loosen the 7/16-inch jam nut on the belt width adjuster.
2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as
needed.
Tip: Turn the set screw in (clockwise) to increase the distance between the
sheaves and out (counterclockwise) to decrease the distance.
3. Tighten the jam nut.
90
MAINTENANCE
.010-.030 in.
(.25-.75 mm)
Clutch System
Torque Stop
Periodically check torque stop
clearance. With clutches in
proper alignment, the torque stop
clearance should be .010-.030
inch (.25-.75 mm) from the
engine case.
Adjust if necessary, and lock the
jam nut.
Tool Kit
A tool kit is included with each
machine for emergency and routine maintenance. Always keep
the tool kit with the snowmobile.
Chain Tension
Maintain the proper chain tension as outlined on page 80.
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
Polaris dealer.
91
MAINTENANCE
+
Track
Track Inspection
WARNING! Broken track rods can cause a rotating track to come off the
machine, which could cause serious injury or death. Never operate with a
damaged track. Never rotate a damaged track under power.
1. Using a hoist, safely lift
and support the rear of the
snowmobile off the ground.
2. Rotate the track by hand to
check for possible damage.
3. Carefully examine the track
along the entire length of
each rod (+). Bend the
track to check for breakage.
4. Replace the track if any rod
damage is found.
92
MAINTENANCE
Track
Track Lubrication
WARNING! Operating with insufficient lubrication between the rail slide and
track guide clips can cause track failure, loss of vehicle control and loss of
braking ability, which can result in serious injury or death. Avoid operating for
extended periods on ice and other surfaces that have little or no snow for
lubrication.
The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new rail slide can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.
Tip: If excessive rail slide wear occurs due to poor snow conditions, additional
wheel kits are available. See your dealer for more information.
Tip: Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.
93
MAINTENANCE
WARNING
Track
Moving parts can cut and crush body parts. When performing the checks and
adjustments recommended on the following pages, stay clear of all moving
parts. Never perform track measurement or adjustments with the engine run-
ning.
Track Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only
after the track is warmed up and limber.
WARNING! Improper track tension can cause serious damage to the
snowmobile, which can result in loss of vehicle control and serious injury or
death. Always maintain the track tension as specified.
1. Turn the engine off.
2. Lift the rear of the machine and safely support it off the ground.
3. Place the recommended weight or downward pressure on the track
at the distance specified (see chart) ahead of the center of the rear
idler wheel.
4. Measure at the point where the weight is hanging.
Weight Measurement
Location
10 lbs. (4.54 kg) 16 inches (41 cm) ahead of
rear idler shaft
Measurement
3/8-1/2 inch (1-1.3 cm)
5. Check for specified slack between the wear surface of the track clip
and the plastic rail slide.
94
MAINTENANCE
Adjusting
Screw
Locknut
Slack
Measurement
Track
10 lbs. (4.54 kg)
Idler Shaft
Bolt
16 in. (40 cm)
Track
Track Tension
If the track needs adjustment:
6. Loosen the rear idler
shaft bolt.
7. Loosen the locknuts.
8. Tighten or loosen the
track adjusting screws
as necessary to provide equal adjustment
on both sides of the
track.
9. Repeat the measure-
ment on the other side
of the track.
Tip: Check more frequently
when machine is new.
10. Start the engine and
slowly rotate the track
at least five revolutions. Let the track come to a stop (do not apply
brakes).
11. Check track alignment (see page 96) and adjust as necessary.
12. Tighten the locknuts.
13. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).
95
MAINTENANCE
Rails
Track
n Track Alignment
Periodically check that the track is
centered and running evenly on the
slide rails. Misalignment will cause
excessive wear to the track and slide
rail.
1. Safely support the rear of the
machine with the track off the
ground.
2. Start the engine and apply a
small amount of throttle until
the track turns slowly at least
five complete revolutions. Stop
the engine and let the track
come to a stop (do not apply
brakes).
3. Inspect track alignment by looking through the track window to
make sure the rails are evenly spaced on each side. If the track runs
to the left, loosen the left locknut and tighten the left adjusting bolt.
If the track runs to the right, loosen the right locknut and tighten the
right adjusting bolt.
4. After adjustments are complete, tighten locknuts and torque idler
shaft bolts to 35 ft. lbs. (47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
96
MAINTENANCE
+
+
+
+
+
+
Steering System
Steering Inspection
Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in
the illustration.
97
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