Polaris Universal Snow (2000) Owner's Safety And Maintenance Manual

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WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

2000

Universal

Snow

Part No. 9915247 Rev 02

PRINTED IN THE U.S.A.

¯ Adult Vehicle Only : This v ehicle is designed f or adult use only. The vehicle

size, speed c apabilities and control requirement prohibit operation by children.

¯ Operating With A Passenger: (On approv ed models only) Operating a vehicle

with a passenger reduces your ability to control the vehicle due to the added weight and change in weight distribution. Generally,reduc e vehicle speeds and provide added space for maneuvering, since steering control may be reduced.

¯ Excessi ve speeds : This vehic le is capable of high speeds. Exercise extreme

caution when operating in unfamiliar terrain. Buried objects or unev en terrain can caus e loss of control.

¯ Body Protection: Always wear an approved helmet, eye protection and

adequate clothing while operating t his vehicle.

¯ Alcohol Or Drugs: Never consume alcohol or drugs before or while operating

this vehicle.

¯ Night Riding and Limited Visibility: Limited v isibility or excessive speeds may

cause over-driv ing of headlight s resulting i n insuffici ent time to react t o terrain c hanges or avoidance of unexpected obstacles.

¯ Auxiliary Shut Off Switch: This switch is the primary means of stopping this

vehicle in case of an emergency and is located on the top of the t hrottle cont rol assembly. Depress the switch for proper func tion with the engine idling.

¯ Safety Throttle System: This system is a supplementary safety device which

stops the engi ne automatically in the event of a throttl e system malfunction. See the Owner’s Manual for proc edure to ensure proper system operati on.

¯ Vehicle Control: The S teering and braking ability are greatly reduced when

operating on hardpac ked snow, ice or when crossing roads. Reduced speed and extra care are required to maintain vehicle control.

¯ Ski S kag Inspec tion: Inspect ski skags for wear ev ery 500 miles or more of ten

when operating on abrasiv e surf ace conditions. Replace ski skags when worn to 1/2 of original diameter.

¯ Carbide Sk ags and Studs: These items enhance vehicle control on ic e or

hardpacked surf aces. Care must be taken to m aintain a proper balance of s ki carbides to track s tuds to maintain proper v ehicle cont rol. (See the Owner’s Manual for proper use of traction access ories.)

¯ Cargo Rack: If t his vehic le is equipped with a cargo rac k, do not sit in or on the

cargo rack. The combined cargo load and tongue weight on the hitch should not ex ceed 75 lbs . (34 kgs.) Cargo load affects machine steering and braking response.

¯ Rotating Track: Stay c lear of the rotating trac k ass embly. Entanglement may

result.

¯ Unfamiliar Rider: Never permit a guest t o operate this vehic le unless the guest

has read t he Owner ’s Manual and warnings.

¯ Adjustment andS ervice: I f you arenot familiar with safe adjustment and service

procedures, bring your vehicle to a qualifi ed dealer for servicing or adjustment.

¯ Read and understand warnings and the Owner’s Manual before operation.

Severe injury or death can result from not heeding the warnings or understanding the Owner’s Manual.

OIL INJECT ION SYSTEM. UNMIXED FUEL O NLY. CHECK OIL LEVEL WHEN REFUELING.

WARNING

Owner’s Safety

and Maintenance Manual

FOREWORD

Thank you for purchasing a Polaris snowmobile. We believe it is the standard of excellence for all snowmobiles manufactured in the world today. Many years of experience in engineering,design, and development have gone into making your Polaris snowmobile the finest machine we have ever produced.

All machines, no matter how well engineered, requirea certain amount of maintenance. Before using your snowmobile, take a few minutes to read through this manual and familiarize yourself with maintenance and operation procedures. It may be the most important time spent in knowing how to keep your machine running perfectly every day.

If the registration form included with your snowmobile has not been completed by you and your dealer, be certain that it is; and make sure that it is forwardedto us. This completed form is necessary to insure warranty coverage.

This manual also contains important pages devoted to safety and environment. Whether you are a long-time snowmobiler or a newcomer to this exciting winter sport, we urge you to seriously read this information.

Remember, your snowmobile is capable of traveling at high speeds. This performance has been engineered into your Polaris to allow you the ultimate snowmobiling experience. Operators must be aware of risks involved when traveling at high speeds, on iced or hard packed surfaces, at night or in unfamiliar terrain. In addition, young or novice riders who do not have the ability or experience to physically controlthemachine in difficult situations should be instructed toreduce theirspeed until they become skilled riders.

On machines designated for two passengers it is most important that theoperator and rider communicate well and practice cornering techniques, rough terrain riding, etc., so that each is contributing to a safe, enjoyable ride. Keep the running board non-skid pads free of iceand snow and in good conditionfor increasedsafety and passenger comfort. The safe and courteous operation of your snowmobile

- with respect for the environment - will insure you the continued enjoyment of the sport of snowmobiling.

If you should experience any problems with your snowmobile, please return it to your dealer. He hasreceivedtrainingwhich will enable him to perform any required repairs. Should any additional assistance be required, your dealer will work with our technical services department to resolve any problems.

All of us at Polaris would like to extendto you our best wishes for plenty of fun-filled, safe snowmobiling pleasure with your new Polaris.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polarisowners likeyou, peoplewho have chosen thefinest recreationalvehicle available,people who share an interest in Polaris and its products.

Once your new vehicle’s warranty is registered, you will receive a PRO Family membership packet that will include:

A letter of welcome to the PRO Family

A PRO Family card with your name and membership number

A colorful sticker of the PRO logo

A PRO merchandise brochure and order form.

As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the PRO Family

The chance to buy insurance for you Polaris vehicle. The toll-free insurance

telephone number is: 1-800-473-0111

The chance to arrange travel through the Polaris Travel Center. The toll-free

travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that provide input

into the Polaris vehicles of the future

The chance to serve as a PRO Field Evaluator and provide feedback on your

new vehicle

The chance to take part in national PRO snowmobile, ATV or personal water-

craft rides

The chance to purchase exclusive PRO Family merchandise

And more!

To order PRO merchandise, you’ll complete the order form you receive with your membership packet, take the form to your Polaris dealer and pay for the merchandise. The merchandise will be shipped directly to your home from the PRO merchandise fulfillment center.

Watch for your PRO membership packet and the next issue of PRO Spirit magazine. This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities.

Enjoy your new Polaris vehicle and welcome to the family--The Polaris PRO Family.

TABLE OF CONTENTS

UNDERSTANDING WARNINGS 1................................

SAFETY WARNING AND OPERATION DECALS 2-9...............

OPERATION WARNINGS 10-24.................................

PRESERVATION OF THE ENVIRONMENT 25.....................

IDENTIFICATION AND SPECIFICATIONS 26-30...................

OPERATION 31-44.............................................

BATTERY 45-47................................................

MAINTENANCE 48-105.........................................

SUSPENSION 106-134........................................

TROUBLESHOOTING 135-141.................................

ACCESSORIES 142...........................................

SERVICE AND WARRANTY 143................................

WARRANTY 144-147..........................................

INDEX 148-149...............................................

UNDERSTANDING WARNINGS

SAFETY ALERT

The following precautionary signal words are used throughout this manual to convey the following messages:

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!

WARNING

Indicates a potential hazard which could result in serious injury or death.

CAUTION

Indicates a potential hazard which may result in minor personal injury or damage to the snowmobile.

NOTE

The word “NOTE:” in thismanualwill alert you to key information or instructions.

SAFETY WARNING AND OPERATION DECALS

WARNING

Driving a snowmobile requires your full attention. Do

not drink alcohol or

use drugs or medications before or while driving as they will reduce your alertness and slow your reaction time. In most states and provinces it is prohibited by law to drive while intoxicated or under the influence of drugs.

Be smart, be safe, don’t drink and drive!

SAFETY WARNING AND OPERATION DECALS

WARNING

Polaris Indys are high performance snowmobiles capable of traveling at very high speeds. Because of this, extra caution must be observed to ensure operator safety. Particular caution must be taken to make sure that the snowmobile is in excellent operating condition at all times. As with any performance snowmobile, we strongly recommend the operator check major and vital safety components each time before riding.

All Polaris snowmobiles have been designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modification; especially those which increase speed or power. The machines may become aerodynamically unstable at speeds above those for which they are designed. There is also a significant possibility of loss of control at higher speeds.

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers do not install on a Polaris snowmobile any equipment which is intended to increase the speed or power of the machine, or make any other modifications to the machines for these purposes. Any modifications to the original equipment or the snowmobiles substantially increase the risk of bodily injury. Be aware that these modifications may create a substantial safety hazard.

Polaris hereby informs you that the warrantyon a snowmobile is terminated on the entiremachineifany such equipment has been added to the machine or any modifications have been made to the machine which increase its speed or power.

We also advise you to strictly follow the recommended maintenance programoutlined on pages 48-100. This preventative maintenance program is designed to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at various mileage intervals.

SAFETY WARNING AND OPERATION DECALS

Your snowmobile is not a toy. It is a well-engineered and well constructed recreational vehicle. The following information is provided to aid you in its safe operation.

NOTE: Warningdecalshave been placed onthe vehicle for your protection. Read and follow the instructionson each decalcarefully. In the event any decal becomes illegibleorcomes off,contactyour Polaris dealerfor a replacement. Any safety decal needing replacementwillbe providedby Polarisat no charge. The part number is printed on the decal.

CAUTION: Although your Polaris has been designed to provide you with a safe, reliable snowmobile, much of its safety depends on the operator. Improper use of this snowmobile or failure to maintain it in good operating condition can result in injury. To reduce this possibility, read the following important safety information.

SAFETY WARNING AND OPERATION DECALS

D Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings.

D Never consume alcohol or drugs before or while operating this vehicle. D Night riding, limited visibility, or excessive speeds may cause

over-driving of headlights resulting in insufficient time to react to terrain changes or avoid unexpected obstacles.

D This vehicle is capable of highspeeds. Buried objects or uneven terrain can cause loss of control. Exercise extreme caution when operating in unfamiliar terrain.

D This vehicle is designed for adult use only. The vehicle size, speed

capabilities and control requirement prohibit operation by children.

D Operating this vehicle with a passenger (On approved models only) reduces your ability to control the vehicle due to the added weight and change in weight distribution. Reduce vehicle speeds and allow added space for maneuvering, since steering control may be reduced.

D Alwayswear an approved helmet, eye protectionand adequate clothing while operating this vehicle.

D The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in case of an emergency and is located on the top of the throttle control assembly. Depress the switch to stop the engine and vehicle. Routinely check this switch for proper function with the engine idling.

D The steering and braking ability are greatly reduced when operating on hard packed snow, ice or when crossing roads. Reduced speed and extra care are required to maintain vehicle control.

D Carbideskags and studs enhance vehicle control on ice or hard-packed surfaces. Care must be taken to maintain a proper balance of ski carbidesto track studs to maintain proper vehicle control. (See the Owner’s Manual for proper use of traction accessories.

D Never permit a guest to operate this vehicle unless the guest has read the Owner’s Manual and warnings.

WARNING

(Text Below)

SAFETY WARNING AND OPERATION DECALS

7075457

(Text Below)

BEFORE STARTING ENGINE: Check throttle and brake for proper operation. Check to see that hood is securely latched. Check surroundings to verify clear operation area. Determine that steering is free and functional.

BRAKE LEVER LOCK: May relax when used forlong periods. Do not leavebrake engaged for more than five minutes.

ALWAYS:Be seated and in position to control vehicle. Stop engine beforeattempting adjustments. Know the limitations of the vehicle and your skills as a driver. Understand your Owner’sManual. Wear clothingdesigned for snowmobiling. Stops from high speed may cause fading or unexpected loss of braking ability.

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

If you do not have the Owner’s Manual for this vehicle, call 1-800-324-3764 to have one provided at no charge.

SAFETY WARNING AND OPERATION DECALS

STAY CLEAR O F T RACK. DO NOT SIT O N SEAT BACK. ENTANGLEMENT WITH THE TRACK OR A FALL FRO M SEAT BACK CAN RESULT IN SEVERE INJURY O R DEATH.

WARNING

AVERTISSEMENT

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.

N’opérez pas le moteur lorsque le capot est ouvert. N’effectuez aucun ajustement lorsque le moteur est enmarche. Ne faites pas fonctionner le moteurlorsque ce garde de sécurité est ouvert. Ne jamais laisser le moteur en marche lorsque la corroie d’entraînement est enlevée. Ne réparez jamais l’embrayage vous-mêmes, voir votre concessionnaire.

WARNING

AVERTISSEMENT

1. Stay clear of track. • Ne pas s’approcher de la chenille

2. Do not sit on seat back or cargo area. • Ne pas s’assoir sur le siège à l’arriè re du compartiment à bagages.

3. Combined cargo and tongue weight should not exceed 4 0 lbs. (18 kg). C argo load affects machine steering response. • Le poids combiné des bagages et de l a barr e d’attela ge ne doit pas dépasser 18 kg (40 livres). Le poids des bagage s affecte la réponse de la direction de la machine.

7073290

1. Stay clear of track.

2. Do not sit on seat back or cargo area.

3. Combined cargo and tongue weight should not exceed 40 lbs. (18 kg). Cargo load affects machine steering response.

SAFETY WARNING AND OPERATION DECALS

VEHICLE CAPABLE OF EXCESSIVE REVERSE SPEED!

Reverse operation can be dangerous even at low speeds. Steering control becomes difficult in reverse. Misuse of reverse can result in injury. Avoid turning at sharp angles in reverse.

Transmission may not always be in the gear indicated by the shift lever. Always apply throttle slowly.

On machines with reverse it is especially important to maintain track tension as specified in the owner’s manual. If specified track tension is not maintained severe damage to the machine may occur, which can result in loss of vehicle control. Loss of vehicle control can result in severe personal injury or death.

For More Info: See Operator’s Safety and Maintenance Manual supplied with reverse kit.

SHIFT PATTERN

Make sure lever is shifted completely to forward or reverse position. Do not force into reverse. If not able to shift to reverse, apply throttle gently to move vehicle. CAUTION: Do not attempt to shift until machine has come to a complete stop or chaincase damage may occur.

(Text Below)

Models Equipped With Reverse Only

NOTE: Illustration of shift pattern may vary. Your model may differ.

SAFETY WARNING AND OPERATION DECALS

Release pressure before removing cap. Cooling fluid must be up to the base of the pressure cap in hot or cold conditions.

Refer to the Owner’s Manual for fluid level in overflow bottle.

CAUTION

ATTENTION

Some Liquid Cooled Models

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

DO NOT OPERATE WITH INTAKE SILENCER REMOVED.

NE PAS OPERER LORSQUE LE SILENCIEUX DE LA PRISE D’AIR EST ENLEVE.

OPERATION WARNINGS

Before Starting The Engine

Read and Understand Your Owner’s Manual

Read the Owner’s Manual completely now, and re-read it occasionally. We have attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling.

Check Throttle and Brake for Proper Operation

The throttleand brakearethe primarycontrolsof yoursnowmobile. If eithershould malfunction, a serious loss of control could result.

When checking the throttle, make sure the control lever willcompress evenly and smoothly. When the lever is released, it should immediatelyreturn to the idle position without binding or hesitation. If the throttle does not function smoothly, do not attempt to start the engine. Have the throttle serviced before starting the engine.

The need for a properly functioning brake is vital. This snowmobile is equipped with the highest quality brake system available. The brake must be checked for correct operation before starting the engine. See page 13 for details.

Check for Proper Operation of Steering System

Check for proper operation of the steering system by manually turning the skis completely to the right and to the left. If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage. Make certain all greasable components are properly lubricated.

Single Rider Snowmobiles

Some Polaris snowmobile models are designed for a single occupant only. A decal on the console of these models indicates single occupant operation.

WARNING/AVERTISSEMENT

This vehicle is designed for operator only.

“NO PASSENGER”

Ce vehicule est concu pour ne transporter

que le conduc teur.

“AUCUN PASSAGER”

WARNING/AVERTISSEMENT

OPERATION WARNINGS

Driving 2-Up

When operating a 2-Up machine with a passenger, the driver should be aware that more space will be requiredto make turns, and alonger distancewillbe necessary for stopping. Lower speeds should be observed whenever riding 2-Up.

CAUTION: Always make certain the passenger remains seated behind thedriver, facing forward, with both feet placed firmly on the running boards. Reduce operating speed and be particularly careful to avoid “jumping” your snowmobile.

Some Polaris snowmobile models are designed for two occupants. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. Machines designated as double occupant should never be operated with more than two people on board. When traveling with a passenger aboard, it is the driver’s responsibility to operate the machine in a safe manner. Remember that control becomes more difficult with two people on board. Reduce speeds to retain control!

WARNING

Use of a backrest can hinder operator weight shifting. This may affect control of this rider-active vehicle in certain extreme driving situations.

Track Inspection

Driving at wide-open throttle for extended periods of time in marginal lubrication could severely damage track rods, break track edges, and cause other track damage. Examples of marginal lubrication would include lakes without snow cover, icy trails and no-snow conditions.

Always inspect for damage before using the vehicle. Use of traction products such as studs, ice growsers, paddles, etc. will increase the possibility of track damage and/or failure. Operating the snowmobile with a damaged track will increase the possibility of track damage and/or failure, which could cause loss of control resulting in severe injury or death.

NOTE: Track damage or failure caused by operation on ice or poor lubrication conditions will void the track warranty.

Do Not OperateEngine With Intake Silencer or FilterRemoved

When operatingengine with intakesilenceror filterremoved,damage to the engine may occur.

WARNING/AVERTISSEMENT

This vehicle is designed for operator and

“ONE” passenger only.

Ce vehicule est concu pour ne transporter

que le conduc teur et “UN SEUL” passager.

WARNING/AVERTISSEMENT

OPERATION WARNINGS

Stay Clear of Track

During warm-up and operation, stand clear of the rotating track. Do not use too much throttle during warm-up or when track is free hanging. Entanglement and serious injury or death may result.

Do Not Operate Engine With Clutch Guard Removed

The clutch guard is designed to protect the operator from metal parts in the event the clutch should fail. Although the chance of failure is extremely remote, do not defeat the purpose of the guard by removing it. It is provided for your safety.

Never Run Engine With Drive Belt Removed

Operation of the engine with the belt removed can result in serious over-speed condition. Any servicing which requires operation without a belt must be done by your dealer.

Never Service Clutches Yourself - See Your Dealer

The clutch is a complex mechanism which operates at high rotational speeds. Each clutch is dynamically balanced before installation. Any tampering by the owner may disrupt this precision balancing and create an unstable condition.

Seat Back/Cargo Carrier

Do not sit on seat back orcargo area. Do notexceed carrier and rack weight limits. Cargo load affects machine steering response.

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operatethis vehiclehave an increased risk of overturnsand loss of control whichcouldresultin serious injury or death.

OPERATION WARNINGS

Hydraulic Brakes

The need for a properly functioning brake is vital. Polaris snowmobiles are equipped with the highest quality hydraulic disc brake system available. The following items must be checked each time before startingthe engine to assure proper operation.

Brake Lever Travel

When the brake handle is depressed (A) , it should move no closer than 1/2″ (1.3 cm) from the handgrip. Excessive travel indicates low fluidlevelorairin the hydraulic system. If the lever travel is excessive, refer to the brake bleeding information on page 69.

Lever Feel

A hydraulic system multiplies the force of your hand squeeze on the brake lever. Proper operation depends upon an adequate air and moisture-free supply of hydraulic brake fluid in the system. If the brake lever feels “spongy” when squeezed, the level and condition of the fluid must be checked; as well as checking for the presence of air in the fluid system. Referto page69 for more informationor contact your dealer for service. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. We recommend the use of Polaris brake fluid (PN 2870990).

WARNING

Continued abusive brake application with a “spongy” brake condition may cause a complete loss of brakes; which could result in severe injury or death.

Mechanical Brakes

Brake Lever Travel

Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance B should be no more than 3/4″ (1.9 cm).

Excessive travel indicates a need to adjust the brake cable adjuster. Refer to the mechanical brake adjustment information on page 72.

OPERATION WARNINGS

Park Brake Lever Lock

1. Brake Handle

2. Park Brake Lever Lock (Not all models are equipped with a park brake)

3. Master Cylinder Reservoir

4. Master Cylinder Cover

5. Fluid Level Indicator

Your snowmobile has a brake brake lever lock. It is located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary (e.g. when parked on an incline) for a period of five minutes or less. To apply lock, squeeze brake handle and push forward on brake lever lock. Hold lock forward and release brake handle. To release lock, squeeze brake handle until lever returns to the unlock position. The park brake light on the console will be lit when the park brake lever lock is set and the engine is running. It is also lit when the service brake is in use. If the park brake light does not come on when park brake or service brake is in use, have it serviced by your dealer.

WARNING

If the park brake leverlock is left partially or entirely engaged while riding the snowmobile, it could cause overheating of the brakes which could result in damage to the brake caliper. In extreme cases it could cause a fire which could result in serious injury or death.

Check to See That the Hood is Securely Latched

The hood of the snowmobile protects the operator from moving partsaswellasaiding in sound emission control and various other functions. Under no circum- stances should your snowmobile be operated with the hood open or removed.

OPERATION WARNINGS

Auxiliary Shut-Off Switch

Check auxiliary shut-off switch for proper operation. Push down to stop engine. Pull up to release and start engine.

Tether Switch (accessory on all models)

Check tether switch for proper operation.

Remove Ignition Key

Don’t tempt anyone to stealor ride your snowmobile without permission by leaving the key in the ignition.

Lighting Check

Check headlight high and low beam, taillight and brake light for normal operation.

Check Surroundings to Verify Clear Operating Area

It is most important to assure yourself that you have a clear area all around your snowmobile, including an area clear of bystanders. Remember that the possibility always exists of some sideways vehicle movement, or a little more throttle than intended; or debris may be thrown by the track. If you are assured of a clear area surrounding you before you start, you can devote your full attention to operating the snowmobile.

Be Seated and in Position to Control the Vehicle

Improper operator position on the snowmobile can be the source of serious injury. Remember that operating a snowmobile does require skill and balance for proper control, and an improper position can seriously reduce your ability to control your snowmobile. The style of positioning will vary from person to person as they become more skilled; but under most conditions the proper position is to be seated, feet on the running boards, and in a comfortableposition for proper throttle,brake, and steering control.

WARNING

Your snowmobile is propelled by a revolving track which must be partially exposed for proper operation. Serious injuries may be caused by operator carelessness resulting in hands, feet, or clothing becoming entangled in the track. Be alert. Remember, being properly seated keeps you 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 personal injury or death.

OPERATION WARNINGS

Stop Engine Before Attempting Adjustments

WARNING

The snowmobile engine compartmentcontains moving parts. Shields and guards have been provided for your safety, but it is still possible to carelessly get your hands or fingers into a moving belt or a rotating shaft. For thisreason neverattempt adjustments with the engine running. Serious personal injuries can result. The proper method is to turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then re-start the engine to check its operation. The same is true of track alignment. If the track must be re-aligned, it is recommended that this service be performed by your dealer.

Always Wear Clothing Designed for Snowmobiling

Clothing designed for snowmobiling is warm, comfortable and safe.

WARNING

Always wear an approved helmet and eye protection. Don’t wear loose clothing or long scarves because they can easily become entangled in moving parts. Also, be aware of the weather forecast and especially the wind chill. A table is provided on page 19 for your reference. Be prepared. Be warm and comfortable.

Know the Limitations of the Machine and Your Skills as a Driver

D Observe state and local laws governing snowmobile operation. They have

been established for your protection.

D Traveling at night requires extra caution. Check both headlight and taillight to

ensure proper operation. Do not “over-drive” your headlight beam. A good rule to follow is to be able to bring your machine to a stop in the distance illuminated by the headlight. High speed driving at night is dangerous and unwise, and could result in severe personal injury or death.

D Be courteous to oncoming traffic by dimming your headlightsand lowering your

vehicle speed. Your snowmobile is equipped with a high outputhead lamp system that can cause discomfort to operators of oncoming vehicles if the headlight is not dimmed.

OPERATION WARNINGS

D Wire fences are a serious

hazard. Unless you are thoroughly familiar with an area, you should always be on the alert for fences. Single strands are especially dangerous, since there can be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Reduce speed when traveling near poles, posts, or other obstacles. Be

especially alert if you are snowmobiling after dark.

D When travelling on lakes and

streams that are strange to you, always check with local residents or authorities for general information on conditions. Thin ice, open water, and snowmobiles are not compatible. Before riding your machine on a frozen body of water,be sure that the ice is thick enough to support the machine and its operator as well as the force created by a moving vehicle. Variances in snow depth and/or water currents can result in uneven ice thickness. Use common sense and good judgment at all times as drowning may result ifyou and the snowmobile break through the ice.

Ice

Snow

OPERATION WARNINGS

D Remember, the sound of your ma-

chine will drown out the sound of approaching vehicles. Look ahead, behind, and to the sides before turning or crossing railroad crossings or highways. Steep embankments may also hide your view. Always leave yourself a way out. Make

sure the way is clear before you cross railroads and other roads and highways.

D Drive defensively when traveling in a group of snowmobilesto avoid accidents.

Don’t tailgate. Allow ample stopping distances.

D Always be alert and pay attention to the trail ahead of you. Multiplying speed

(MPH) by 1.5 will equal the approximate number of feet per second your machine travels. Ifyour speed is 40 MPH,your machineis travelling approximately 60 feet per second. This means that if you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH, your machine will travel approximately 180 feet in two seconds.

D When teaching inexperienced operators to ride, set up a nearby predetermined

course. Make sure they know how to drive and control the snowmobile before you allow them to make longer distance runs. Teach them proper snowmobile courtesy. Enroll them in a driver’s training and safety course sponsored by a local or state organization.

OPERATION WARNINGS

Windchill/Temperature Charts

The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.

WIND CHILL CHART (°F)

Estimated

Actual Ther mometer Reading (°F)

ind

pee

MPH

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

Equivalent Temperature (°F)

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

5 48 37 27 16 6 -5 -15 -26 -36 -47 -- 5 7 -68

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

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

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

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

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

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

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

Wind Speeds Greater Than 40 MPH Have

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

40MPHHave

Little Added

Effect

ClothedPerson

)

Danger F rom Freez ing of Exposed Fles h

WIND CHILL CHART (°C)

Estimated

Actual Ther mometer Reading (°C)

ind

pee

KPH

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

Equivalent Temperature (°C)

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

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

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

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

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

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

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

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

Wind Speeds Greater Than

70 KPH Have

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

70KPHHave

Little Added

Effect

ClothedPerson

)

Danger F rom Freez ing of Exposed Fles h

OPERATION WARNINGS

Cold Weather Driveaway

Whenever the machine has been parked for some length of time, especially overnight, always shake loose the skis and track before attempting to put the machine into motion. The throttle should always be opened withenough authority to put the machine into motion, staying within safety limits and with respect to a passenger, on a two passenger machine.

Powder Snow Operation

Your Polaris is designed to operate best on snow. Maneuverability is attained by the steering, skis, and the shifting of your body weight. Maximum control will be attained by shifting body weight. Maneuverability will change for lighter operators or machines carrying a load or a passenger where allowed.

CAUTION: Do not operate for prolonged periods on blacktop, gravel, or glare ice.

It is essential that your machinebe operated under conditions with adequate snow cover, as snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling forthe engine. Failureto doso willresultinexcessive wear and damage to the slide rail and track and/or engine.

If the machine becomes stuck in snow, free the running board area, and stepdown the snow in front of the machine so that when the throttle is opened the machine will be able to climb up and over. The operator can then mount the machine and continue.

WARNING: Snow and ice buildup in the underhood area can cause interference with the steering function.

Before driving, be sure that ice and snow are not interfering with full left and right steeringby manuallyturningthe skis tothe leftand right. If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage. Snow screen and bib kits are available through your dealer to help reduce snow and ice buildup.

NOTE: The ability of the machine to travel in adverse conditions will improve as the operator gains experience.

OPERATION WARNINGS

Hard Packed Snow

WARNING

Steering and braking control are substantially reduced under packed snow or icy conditions.

Excessive shifting of operator body weight when turning on hard packed snow or slippery surfaces can result in loss of vehicle control and serious injury. Reduce speed as required to maintain control under these conditions.

Ice

It is dangerous to operateon ice or under slippery conditions. If ice or slip-

pery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface. The chance of “spin-out” increases under these conditions.

Before riding your snowmobile on a frozen body of water, be sure that the ice is thick enough to support the machine and its occupant(s) as well as the force that is created by a moving vehicle. Severe injuryor death can result if the snowmobile and/or its occupant(s) break through the ice.

OPERATION WARNINGS

Hilly Terrain

Exercise caution and good judgement when travelling in hilly terrain.

Crossing a Slope (Sidehilling)

WARNING

Sidehilling can be very dangerous and is not recommended for inexperienced snowmobilers.

Crossing the face of a slope (sidehilling) requires the operator to position his/her weight in order to maintain proper balance. Kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board. This position makes it easier to shift your weight as needed. As you travelacross the slope, lean uphill to position your weight on the uphill side.

OPERATION WARNINGS

Riding Uphill

Hill climbing may be accomplished by using one of two methods, depending upon the steepness of the hill.

Sidehilling may be used if there are few obstacles on the hill. The operatorshould assume a kneeling position (as in Sidehilling), keeping body weight on the uphill side at all times. Maintaining a steady, safe speed, approach the hill at an angle, continuing as far as possible in this direction;then switchto the opposite angle and riding position.

The direct climb method requires extreme caution. The operator should assume a standing position with body weight kept low and forward, accelerating before the start of the climb and then releasing throttle pressure enough to prevent track slippage.

In either type of climb,the operatormust slow down when reaching the crest of the hill. Be prepared to react to obstacles, sharp drops, or other people or vehicles which may be on the other side of the hill.

If you are unable to continue up a hill, turn the machine downhill before it

loses momentum. If this is not possible, spin the track just enough to dig in so the machine won’t roll 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, pointing the machine back downhill. Once the snowmobileis pointed downhill,mount the machine, restart the engine, releasethe parking brake, and descend the hill.

Riding Downhill

When riding downhill, keep speed at a minimum. It is important to apply just enough throttleto keepthe clutchengaged whiledescending the hill. This willallow use of the engine’scompressionto help slow the machine, and keep the snowmobile from rolling freely downhill.

WARNING

Use extreme caution when applying the brake during a descent. Excessive braking will cause the track to lock, resulting in loss of control.

OPERATION WARNINGS

Responsible Driving

If you operate the snowmobile improperly, you will cause situations which will exceed your driving skills. Each snowmobile handles differently,and even if you are a seasoned driver, it is strongly recommended that you spend some time getting the feel for this particular machine before attempting ambitious maneuvers. If you are new to snowmobiling, take enough time to acquaint yourself with the machine and what it will and won’t do under various conditions.

Acquire a feel for your machine before attempting ambitious maneuvers.

The snowmobile depends on your body position for proper balance in executing turns, traversing hills, etc. It’s best to start on a smooth level area to begin building your operating experience.

Before you let someone else use your snowmobile, be sure you know the

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

Don’t “jump” your snowmobile. Jumping can injure your back because of

spinal compression. The seat and suspension of your snowmobile have been designed and constructed to give you protection, but they do have limits. Your snowmobile is not intended for this kind of use.

PRESERVATION OF THE ENVIRONMENT

We recommend that you drive your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

Probably the most publicizedsubjectwithregard to snowmobilesis noise. The Society of Automotive Engineers (SAE), which is the standard-settingbody for snowmobiles,has recommendedthatsnowmobiles conform to prescribedsoundlevels. Your Polaris snowmobile has been engineered to conform to these SAE standards.

In order to be meaningful,allregulations require the cooperation of the snowmobile driver. Muffling systems, designed to reduce noise levels, should not be altered or removed. Snowmobile drivers must be aware that they have a public responsibilityto operate their snowmobiles with concern forothers. As a snowmobile operator you may not realize the sound of your snowmobile may annoy non-snowmobilers. We are attempting to do our part through the manufacture of quieter machines, and we also ask your help in the effort to further reduce the impact of noise.

Air Pollution

As a part of Polaris’ plan for the snowmobile’s compatibility within the environment, our engineers are investigating 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 technological research, we also suggest that governmental agencies, manufacturers, distributors, dealers, ecologists, and other interested parties work together to develop dataon environmental topics. We will continue to participate in this type of study so that someday we may find the answers to these difficult issues.

Environmental Protection

As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety trainingprograms which also encourage protection of our environment,wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. It is very important that we encourage them as well as become actively involved ourselves.

Respect your snowmobile; respect your environment;

and you will earn

the respect of everyone.

IDENTIFICATION AND SPECIFICATIONS

Vehicle Nomenclature

Refer to illustrations on following pages. NOTE: Illustrations are a general representation. Your model may differ.

1. Hood 13. Suspension

2. Headlight 14. Nosepan

3. Windshield 15. Trailing Arm

4. Handlebar 16. Skis

5. Seat 17. Front Bumper

6. Storage/Rear 18. Console

7. Taillights 19. Vehicle I.D. Number (Right Side)

8. Backrest 20. Rear Bumper

9. Tunnel Extension 21. Passenger Hand Hold

10. Passenger Hand Hold Strap 22. Lifting Hand Hold

11. Track 23. Snow Flap

24. Mountain Bar

Vehicle Nomenclature, Cont.

IDENTIFICATION AND SPECIFICATIONS

Vehicle Nomenclature, Cont.

IDENTIFICATION AND SPECIFICATIONS

Vehicle Nomenclature, Cont.

IDENTIFICATION AND SPECIFICATIONS

Controls and Instruments

1. Headlight Dimmer Switch (2 Position)

2. Fuel Filler Cap/Gas Gauge

3. Auxiliary Shut-Off Switch (Push/Pull). Operation found on page 40.

4. Throttle Control

5. Recoil Starter Handle

6. Choke Control

7. Ignition Switch

8. Tachometer (may include indicator

/ warning lights)

9. Speedometer (may include indicator / warning lights)

10. Brake Lever

11. Low Oil Warning,Brake Light, High Beam, Temp, premium fuel options

12. Accessory Indicators

13. Safety Decals

14. Hood Hold Down

15. Handlebar Grip Warmer Switch

16. Thumbwarmer Switch

17. Thumbwarmer/Handwarmer

Switch

18. Reverse Lever

19. Fuel Gauge

20. Temperature Light

21. Tether Switch

22. Power Plug

23. Electric Shock Absorber Gauge

General Representations Your Model May Differ

IDENTIFICATION AND SPECIFICATIONS

Backrest

1. Backrest Cushion Adjuster

2. Backrest Adjuster Cable

3. Grab Bar Adjustment Knob

4. Passenger Handwarmer Switch

5. Wind Deflector

6. Backrest Adjustment Lever

7. Passenger Hand Hold

OPERATION

Carburetion

Proper carburetor adjustment is critical, since a mixture too lean (toomuch air, too littlefuel) will result in overheating of the combustionchamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failure. A lean mixture can be the result of fuel line restrictions, foreign matter in the carburetor, clogged fuel filter, etc.

A mixture too rich (too much fuel, too little air) is also unfavorable because it can foul plugs and cause generally poor engine performance.

All carburetors have been pre-set at the factory for adequate fuel supply. Higher altitude operation may require different adjustment and settings.

RMK models are pre-setto operate at altitudes of 6000-9000 feet above sea level.

WARNING

Carburetoradjustmentsmust be performed by your dealer,since mistakes can result in possible operator safety hazards as well as serious engine damage.

Remember,correct setup provides engine RPM within its given power band at full throttle settings and also provides maximum efficiency and operation at all other throttle openings. Your dealer has the training and tools required to perform any adjustments for you.

WARNING

Engine damage may result if jetting or clutching is wrong. Never service clutches yourself. See your dealer.

Drive System

1. Engine

2. Torque Converter (Drive Clutch)

3. Driven Clutch

4. Drive Belt (Neutral Position)

5. Drive Belt (Full Upshift Position)

6. Upper Chaincase Sprocket

7. Chain

8. Lower Chaincase Sprocket

9. Chaincase Oil Level

10. Drive Shaft

11. Tr ac k

OPERATION

Lubrication

The fuel and oil which enter the engine through the fuel and oil injection systems provide the only source of engine lubrication, and must be of the highest quality.

You can understand the importance of proper lubrication when you realize that at 6000 RPM the crankshaft is rotating 100 revolutions per second.

Premium 2-Cycle Lubricant

The only oil recommendedfor this fuel system is Polaris brandoil. CAUTION: Engine warranty coverage may become void if other brands are substituted.

Polaris Premium Gold Synthetic Lubricant is the most advanced formulation of oil available for today’s 2-cycle engines. Over twenty months of lab and field tests have resulted in a new generation of 2-cycle lubricant. Polaris Premium 2-Cycle Lubricant addresses the problem of lowerqualityfuel;keeping ring grooves cleaner with less ring sticking and providing improved overall engine cleanliness. With new generation lubricity technology, it excels in meeting the lubricity demands of today’sfaster, more preciselyengineered 2-cycle engines. It is the optimum oil recommended for liquid 2-cycle engines and performswell in allaircooled 2-cycleengines. We believe this oil is the best product available in the market today, and strongly recommend its use in all of our products.

Never mix other brands of oil since they may be incompatible, resulting in sludge formation, filter blockage and reduced cold weather flow rates.

Oil Injection System

The fuel-to-oil mix ratios are controlled by the oil pump and the movement of the oil pump arm. The fuel-to-oilmix ratio corresponds to the engine’sRPM and throttle valve opening.

Always fill the oil reservoir when refueling. NOTE: Mix two pints of Polaris injectionoil to the first tankfulof gasoline. In addition

to the lubrication supplied by the injection system, this will ensure proper engine break-in.

CAUTION:

Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately. Continue using premixed fuel until the oil injection system can be inspected.

Low Oil Indicator Light

The low oil indicator light is standard on most models.

CAUTION:

When the low oil indicator light is on, it indicates that oil must be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine can be operated as long as oil is visible in the oil tank. If oil is not visible, continued operation may cause severe engine damage.

OPERATION

WARNING

Never mix brands of two cycle oil. Serious chemical reactions can occur, causing injection system blockage resulting in severe engine damage and voiding of engine warranty.

CAUTION:

Always maintain the oil level in the oiltank above the low level line. The low oil indicator light will indicate when to add oil. However, the oil level should always be checked when refueling. NOTE: In the illustration, * indicates low oil level.

This is especially important when the machine is operated in mountainous terrain. Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage.

NOTE: Always use a Polaris oil cap, never substitute. Your Polaris oil cap may be vented to allow proper oil flow.

At low level mark add 1 U.S. quart.

NOTE: Not all models

have a coolant bottle attached to the oil tank.

OPERATION

Fuel

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

OPERATION

Fuel

The fuel used in the Polarisengine is as important to engine life and performance as the lubricant used.

Most Polaris engines are designed to run on 87 octane non oxygenated or 89 octane oxygenated pump gasoline. There is a great deal of variability in the quality of the 87 octane gasoline available across the country. We encourage the use of premium fuel when possible. NOTE: XCR models require premium gasoline.

Consult your Owner’s Manual Supplement for specific minimum octane requirements.

Premium Fuel Switch

Some Polaris snowmobiles are equipped with a key function that will adjust the timing on the machine as you change fuels.

Most high performance machines require the use of premium fuels. When premiumfuelisnot available,thereis a risk of engine damage when other fuels are substituted.

When using fuels with a pump posted octane rating of 91 or higher, turn the key switch to “ON/PREM”. When the engine is started a yellow “Premium Fuel” light illuminates on the instrument panel. When the key is in this position, the fuel must be a minimum of 91 octane.

If you are uncertain about the quality or octane ratingof the fuel you are using, turn your key switch to “ON/REG”. The “Premiumfuel” light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not recommend using fuel with lower than 87 octane.

Running your machine on “ON/REG” will protectyour engine from damage caused by low octane fuels. It is very important to the life of your engine that you areaware of and use this feature.

Premium Fuel Setting

Regular Fuel Setting

OPERATION

Fuel Reserve Capacity

On equipped models, when the fuel gauge reads “RES”, there are approximately 2 gallons of fuel left in the tank.

Fuel System Deicers

If you are using non-oxygenated fuel, Polaris recommends the regular use of Isopropyl base fuel system deicer (PolarisPN 2870505). Add1 to 2 ounces pergallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean mixtures. Neveruse deicers or additivesthatcontainmetha- nol. Use only isopropyl fuel system deicers.

If using oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives are not required and should not be used.

CAUTION:

Prolonged exposure to petroleumbased productsmay damage paint. Always protect painted surfaces when working with fuel.

It is recommended that plastic side panels be removed whenever servicing requires tipping the machine on its side for a period of fifteen minutes or more.

Tool Pouch Clip

Some Polaris snowmobiles are equipped with a tool pouch clip which is located inside of the flap on the back of the seat. Using this clip will secure the tools, preventing them from freely bouncing around during snowmobile use.

Tool Pouch

Tool Clip

OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free machine life as proper break-infor a new or rebuilt engine. Familiarize yourself and others with the following procedure for your Polaris snowmobile.

Premix the first tank of gasoline with one pint of Polaris injection oil for each 5 gallons of fuel. This, in addition to the lubrication suppliedby the injection system, will assure proper engine break-in. IMPORTANT: Before operating with unmixed fuel, make sure oil is being drawn from the oil tank.

WARNING

D Never mix brands of two cycle oil. Serious chemical reactionscan cause injec-

tion system blockage, resulting in severe engine damage and voiding of engine warranty. The only oil recommendedfor this system is Polaris injection oil. This oil has been speciallyformulated for all temperatures and has extreme coldflow characteristics.

D Do not operate at prolonged full throttlefor the firstthreehours of operation. Vary

the throttle openings and machine speeds. This will reduce friction on all close fitting machined parts and allow them to break in slowly without damage.

D Avoid operating on ice or hard-packed surfaces, roads, etc. The absence of lu-

brication and cooling by snow will lead to overheating of the slide rail and track resulting in premature wear and failure. Reduce speeds and frequently drive into freshsnow to allow adequate cooling and polishing of the sliderail and track surfaces.

D Drive with extra caution during the break-in period. Perform regular checks on

fluid levels, lines, and all important areas of the machine.

With a basic understanding of how the snowmobile works, and withclose attention paid to maintenance tips, you willbe ready to ride. Keep in mind these recommendations as well as those covered throughout this manual.

OPERATION

Pre-Starting

WARNING

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Operation Warnings beginning on page 10.

Important safety items include, but are not limited to:

D Throttle system D Brake system D Steering system

These systems must be checked each time before starting the engine. Incorrect adjustments, damage, or excessive wear due to neglect could result in personal injury and/or damage to the snowmobile.

Starting a Cold Engine (Manual Start)

1. Turn key to “On”.

2. Pull kill switch (shut-off switch) up to “run” position.

3. Flip choke toggle to “Full On” position.

4. Grasp starter handle and pull slowly until recoil engages; then pull to start.

CAUTION:

Do not pull the starter rope to its full extended position or allow it to snap back into the housing as damage can result.

NOTE: Do not depress throttle until engine starts.

5. After engine starts, the choke toggle should be flipped to “Off” position. If the engine slows or wants to stop, intermittent choking to the “Half On” positionis helpful.

Starting a Cold Engine (Electric Start)

1. Flip choke toggle to “Full On” position.

2. Pull kill switch (shut-off switch) up to “run” position.

3. Turn key to “Start” position and crank engine.

4. Afterenginestarts,release key to “On” position and flip choke toggleto “Off”. If the engine slows or wants to stop, intermittentchoking to the “Half On” position is helpful.

NOTE: Do not depress throttle until engine starts.

OPERATION

Starting a Warm Engine

1. Turn key to “On”.

2. Pull kill switch (shut-off switch) up to “run” position.

3. Grasp starter handle and pull slowly until recoil engages; then pull to start.

If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4″ open), and pullthe rope with your right hand. As soon as the engine starts release the throttle.

CHOKE TOGGLE POSITIONS

Off or

Half On or

On or

OPERATION

Auxiliary Engine Shut-Off Switch

To stop the engine in an emergency,push down on the auxiliary shut-off switch (A). This will ground out the ignition and bring the engine to aquick stop. Torestart the engine the switch must be pulled up to the “On” position.

Throttle Safety Switch

Test the throttle safety switch system on a daily basis before the machine is used.

While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration (B). Apply a slight amount of throttle opening. A properly functioning switch must shut down the engine.

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

WARNING

If the throttle safety switch does not shut off the engine in the event of a carburetor/ throttle system malfunction, immediately push down the auxiliary shut-off switch. Do not start the engine until the malfunction has been corrected by your dealer.

If the snowmobile engine stops abruptly when the throttle lever is released, use the following procedure.

1. Turn the ignition switch to “Off”.

2. Visuallyinspect the throttlecable and carburetor(s) to determine what caused the safety switch to activate.

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

OPERATION

WARNING

If the throttle lever does not work properly, do not start the engine.

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

5. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service.

If excessive play develops in the throttle cable, the safety switch may be activated, preventing the engine from starting. Contact your dealer.

If the engine does not start, and throttle safety switch malfunction is suspected, returnthe machine to an authorized Polarisdealerfor service. Ifan emergencyexists and it is necessary to start the engine, the throttle safety switch and auxiliary shutoff switch may be disconnected from the wire harness.

WARNING

With the throttle safety switch and auxiliary shut-off switch disconnected, the ignition key switch must be used to shut off the engine. Do not continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping Procedures

The following chart lists methods for stopping the engine in the event of an emergency.

SYSTEM

WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows drive shaft All

Choke Floods engine 1/2 throttle or less

Auxiliary Shut-Off Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

Refer to page 40 for more information on the auxiliary shut-off and throttle safety switches.

Emergency Starting Procedure

Your machine comes with a tool kit containing essential tools for emergency use. In the event the recoil starter system should fail, take the emergency start strap from the kit and proceed as follows:

1. Open clutch guard.

2. Push on the inner sheave of the secondary clutch and rotate clockwise slightly to relieve belt tension. This allows for easier starting.

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

WARNING

Do not wind the strap around your hand. Severe injury could result.

4. Pull the strap using a sharp, crisp pull so the strap comes free of the clutch.

CAUTION:

Keep all people clear of the snowmobile when using the emergencystartingprocedure.

OPERATION

Pre-ride Warm Up

The following steps must be taken to ensure proper warm up of the engine, drive train and track.

With the snowmobile securely supported by the rear bumper, and approximately 4″ (10 cm) off the ground, use the following procedure.

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

WARNING

Be sure the rear support is stable. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while performing this procedure. Do not use too much throttle during warm up or when track is freehanging. A loose track or flying debris could cause serious personal injury or death.

2. Engage the drive system abruptly and allow it to rotate the track several revolutions. NOTE: The outside temperature will determine the amount of track warm-up required.

3. Shut off the engine and remove the rear support.

4. Grasp the skis by their front loops and move from side to side. This willloosen frozensnow from the ski bottoms, allowing the machine to move forwardmore easily.

5. The engine, drive system and track are now properly warmed up and the machine can be driven following normal safety practices.

6. WideTrakmodels can also be warmed up with the transmissionin neutral and the brake engaged. This will allow the engine to warm without engaging the drive system. NOTE: This should not last more than five minutes.

WARNING

Engine RPM should be at idle before shifting the transmission.

OPERATION

Towing

WARNING

For your safety, the proper function of a tow hitch must be understood before attempting its use.

Do not tow toboggans, sleds, saucers, or any type of vehicle with a rope. No braking power can be applied to an object being towed with a rope.

Only a stiff metal pole connecting the towed object and tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, ensure that the stiff connecting pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the vehicle track and a person riding in the towed object.

Reduced speeds are required when towing to aid in maintaining steering and general vehicle control. Braking ability is also reduced when towing loads. Reduce speed and use caution, as braking distances will increase. Tipover can occur resulting in severe injury or death.

If a situationarises requiring the snowmobile to be towed by another snowmobile, attach the tow rope to the spindles, not the ski loops.

WARNING

Always remove the drive beltfrom a disabled snowmobile or shift the transmission to neutralbeforetowingto prevent serious damage to theengine and drive system.

Daily Storage

Whenever your machine is placed in overnight or daily storagethe following steps must be taken:

D Park the snowmobile on a

level surface and support it at the rear so the track is suspended approximately 4″ (20 cm) off the ground.

D Remove the key and cover

the machine using thePolaris cover available for your model. See your dealer for more information.

BATTERY

Battery Fluid

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper (1) and lower (2) level marks.

To refill use only dis-

tilled water. Tap water contains minerals which are harmful to a battery.

Battery Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash termi-

nals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean rags. Coat the terminals with dielectric grease or petroleum jelly.

Do not allow cleaning solution or tapwatertoenter the battery. It will shorten

the life of the battery.

WARNING

Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing.

ANTIDOTE:

EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of mag-

nesia, beaten egg, or vegetable oil. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.

away. Ventilate when charging or using in closed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

BATTERY

Battery Removal

CAUTION:

Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstallthe negative cable last to avoid the possibility of explosion.

1. Disconnect hold down straps holding battery in position.

2. Remove battery vent tube from battery.

3. Disconnect black (negative) battery cable first.

4. Disconnect red (positive) battery cable second.

5. Liftthebatteryout of thesnowmobile,being careful not to tip it sideways or spill electrolyte.

CAUTION:

If electrolyte spills, immediately wash it off with a solution of 1 tablespoon baking soda and one cup water to prevent damage to the snowmobile.

When your snowmobile is placed in storage for one month or more:

D Remove the battery. D Charge it to the proper level. D Store it in a cool dry place.

It is possible for batteries to freeze at the following charge conditions, resulting in cell damage.

D 100% Charged -75° F(--59° C) D 75% Charged -24° F(--31° C) D 50% Charged 0° F(--18° C) D 25% Charged +13° F (-11° C) D 0% Charged +18° F(--8° C)

Before using the battery, take it to your dealer for testing and recharging.

BATTERY

Battery Installation

WARNING

To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first, black (negative) cable last.

1. Set the battery in its holder. Attach the hold down strap.

2. Install the battery vent line. It must be free from obstructions and securely installed. Route the vent line away from the frame and body to prevent corrosion.

WARNING

If the batteryvent tubeis pinchedorkinked,battery gases could accumulateresulting in an explosion. Avoid skin contact with electrolyteas severe burns can result.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Verify that cables and vent hose are properly routed.

MAINTENANCE

Polaris Recommended Owner Maintenance Program

YourPolaris snowmobile has been engineeredand manufacturedby skilled Polaris personnel to the highest degree of performance and reliability possible. In order to maintain this high degree of performance and reliability your Polaris must be given regular service and maintenance inspections.

We are interested in ensuring your continued enjoyment in snowmobiling with Polaris. To assure you of trouble-free enjoyment, the Polaris Owner Maintenance Program has been developed. If the recommended regular maintenance and service checks are followed, you will be doing your part in keeping your snowmobile in excellent operating condition at all times.

The recommended maintenance schedule on your snowmobile callsfor a service and maintenance inspection at 150 miles (240 km), 1000 miles (1600 km), and 2000 miles (3200 km). These inspections should be performed by a qualified service technician. All necessary replacement parts and labor incurred, with the ex-

ception of authorized warranty repairs,become the responsibility of the registered owner.

If during the course of the warranty period parts failures occur as a result of owner neglect in performingthe recommended periodic maintenance, the cost of such repairs shall be borne by the owner. Please consider the recommended maintenance program illustrated on the following pages as a preventative maintenance program designed to maintain the performance and reliability of your snowmobile in the years to follow.

Weekly Maintenance Check

For best machine performance and safe operation, check these points weekly and before any long distance trip:

1. Track alignment and adjustments

2. Chain (if applicable)

3. Gearcase oil level (if applicable)

4. Drive chain tension (rotate driven clutch back and forth, checking for excessive deflection)

5. Drive belt condition/tension

6. Brake operation, adjustment (Mechanical), fluid level (Hydraulic)

7. Headlights, tail and stop lights

8. Emergency shut off switch operation and throttle safety switch function

9. Suspension mounting bolts (tighten)

10. Steering arm and tie rod ends (check for play or looseness)

11. Ski saddle and spindle bolts (tighten)

12. Suspension front limiter strap bolts (tighten)

13. Condition of front limiter strap

14. Throttle cable condition

15. Coolant level

16. Battery fluid level

MAINTENANCE

Carefulperiodicmaintenance will help keep your vehicle in the safest,mostreliable condition. Inspection, adjustmentand lubricationof important components are explained on the following chart and maintenance pages of this manual.

For continued maximum machine performance and component life, it is recommended that maintenance checks be performed at 1000 mile (1600 km) intervals.

Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

NOTE: The following chart is a guide based on average riding conditions. You may need to increase frequencybased on riding conditions. Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

ITEM

WEEKLY

BEFORE

LONG

TRIP

150MI.

(240 KM)

1000 MI.

(1600 KM)

2000 MI.

(3200 KM)

SEE

PAGE

Check brake operation and adjustment

Daily 69

Test auxiliary shut-off switch Daily 40

Test throttle safety switch Daily 40

Throttle lever operation Daily 10, 40

Check track alignment X 92

Check track tension X 90

Check chaincase oil level X 67

Check gearcase oil level X 68

Check drive chain tension

X 67

Check drive belt condition X 80

Check operation of headlights, taillight, brakelight

X 15

Check and tighten loose s uspension mounting bolts

X 101

Tighten ski saddle and spindle bolts

X 101

Check front limiter strap condition, tighten bolts

X 126

Check ski skags- replace when worn to 1/2 original diameter

X 100

Check hi-fax thickness Replace when worn (Dealer)

X 101

Tighten rear idler wheel bolts X 92

Tighten idler adjus ting bolt jam nuts

X 92

Check spark plug condition X 56

MAINTENANCE

ITEM

WEEKLY

BEFORE

LONG

TRIP

150MI.

(240 KM)

1000 MI.

(1600 KM)

2000 MI.

(3200 KM)

SEE

PAGE

Inspect coolant filter and replace

X X X

Grease ski pivots X X X 52

Grease center steering arm(s) X X X 52

Lubricate steering post support bracket and pi vot (aerosol)

X X X 52

Check cylinder base stud torque on all 600 and 700 Polaris engines. (Specificat ion: 32 ft. lbs ± 2 ft. lbs.) (Dealer)

X X X -

Grease ski spindles X X X 52

Grease lower s teering post pivot

X X X 52

Grease driveshaft bearing X

(and before

storage)

X 53

Check and drain water trap X X

Grease rear suspension pivot shafts

X X 53

Grease jackshaft bearing X

(and before

storage)

X 53

Lubricate throttle cable X X 66

Lubricate choke slide and cable

X X 66

Check clutch alignment and offset

X X 81

Check cooling system level and specific gravity

X X 64

Inspect oil filter and replace X X

Inspect oil line condition X 60

Inspect fuel filter and replace X X 60

Check brake fluid level X X 70

Inspect fuel lines and replace X 60

Inspect exhaust system for weak or mi ssing retaining springs

X 63

Inspect exhaust pipe for cracks or damage

X 63

Inspect clutch sheaves for damage, wear, belt residue

X 80

MAINTENANCE

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

150 Mile (240 km) Initial Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

1000 Mile (1600 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

2000 Mile (3200 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

MAINTENANCE

Adjustments

It is your responsibility as the snowmobile owner to perform preventative maintenance and periodic adjustments. Many of the items listed in this section you can perform yourself. However, at times your snowmobile may need service requiring special tools and technical skills. In these situations, we recommend you contact

your Polaris dealer.

Loose nuts and boltscan reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a quick inspection of these areas will uncover potential problems.

Lubrication

Lubricate the following fittings with Polaris Premium grease (PN 2871066) annually or approximately every 1000 miles (1600 km). The + in the illustration indicates

grease points.

D Spindles, leftand right. The front end of the machine should be raised to permit

better grease entry into the spindle area.

D Rear suspension pivot shafts. Raise the rear of unit. D Lubricate both frontskipivotsatfitting as shown using Polaris All Season grease. D Grease jackshaft and driveshaft clutch side bearings. D Use an aerosol lubricant on the steering post support bracket. D Grease center steering arms. D Grease steering post lower pivot.

Refer to suspension section of this manual for locations of these components. NOTE: A grease gun kit complete with grease and adaptors is available to lubri-

cate all fittings on Polaris snowmobiles. Order PN 2871312.

Aerosol

MAINTENANCE

Coupler Greasing - WideTrak

Grease couplers on driveshaft and jackshaft

NOTE: Grease points in the illustrations are indicated by a +.

1. Jackshaft

2. Driveshaft

3. Transmission

Jackshaft Bearing Greasing

Loosen driven clutch retaining bolt and pull clutch outward to expose bearing and grease fitting. Inject grease into grease fitting in flangette until grease purges out, inside or outside the bearing seal (this should take only 2 pumps). Push clutch back onto shaft and replace clutch retaining bolt. Torque to18 ft. lbs. (2.48 kg/m).

Driveshaft Bearing Greasing

Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside bearing seal (this should take only 2 pumps).

MAINTENANCE

Intake Filter

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

Do not operate machine with the intake filters removed. This can cause carburetor icing resulting in poor fuel economy or carburetor malfunction.

Refer to the next page for the location of the followingcomponents. NOTE: These are general representations, your model may differ.

1. Intake Foam Filter 2. Air Intake box 3. Air Plenum

4. Dash Cowl

CAUTION:

MAINTENANCE

Under Hood Air Intake System

The Indy 340s are equipped with an under hood air intake system which should normally be left open. The door should be closed and latched above 35° F(2° C) for maximum perfor- mance during warm weather operation. Simply pull the strap out and up to latch the door and reverse the procedure to open it.

MAINTENANCE

Spark Plug Selection

Original equipment parts or their equivalentshould always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high willcause engine damage. A spark plug with a heat range which is too low will cause excessive fouling and malfunction.

In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going to operated under extreme heavy duty conditions. This protectsthe engine frominternaldamage in the event that the purchaser actually does operate the engine in this manner. This selection however, could cause the customer who normallyoperatestheengine under medium or lightduty to have spark plug failure. Referto your Owner’s Manual Supplement for the specific spark plug to be used in your machine.

CAUTION:

A plug with a heat range which is too high will always cause engine damage if the engine is operated in conditions more severe thanthatforwhich the spark plug was intended.

A new enginecan cause temporary spark plug fouling even though the heat range is proper, due to the preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization will result.

D Use recommended spark plugs D Proper electrode gap is .028″/0.7mm D Spark plug torque is 18-22 ft. lbs. (2.5-3 kg/m) D Always carry spare spark plugs in case of an emergency

NOTE: Incorrectfuelmixture can oftencause a spark plug to appearto be 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).

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

Normal

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

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled

The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, excessive idling, idle too low or too rich, or weak ignition output.

MAINTENANCE

Spark Plug Removal and Replacement

WARNING

Never attempt to remove the spark plug while the engine is warm. The exhaust system or engine could burn you, causing severe injury.

The spark plug is removed by using the special wrench (1) provided in thetool kit. Remove the spark plug cap. Remove the spark plug by rotating counterclockwise.

Reverse the procedure for spark plug installation. Torque to 18-22 ft. lbs. (2.5-3 kg/m). NOTE: Always check the gap on new spark plugs with a wire gauge.

MAINTENANCE

Water Pump Belt Inspection

Some liquid cooled models will require an inspection of the waterpump belt. This belt inspection interval is 1500 miles (2400 km). Inspect belt width and condition as illustrated and replace if cracking or worn past the width service limit (.250″ /

6.35mm). If the belt needs tobe replaced, see your Polaris dealer.

Replace if width is less than .25″ (6.35mm). Nominal new width is .345″ (8.75mm).

MAINTENANCE

Water/Sediment Trap Service

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

WARNING

When draining the traps, fuel spillage will occur. Be sure to work in a wellventilated area away from anything which may cause the fuel to ignite such as open flames, sparks, heaters, trouble lights, cigarettes, etc.

Cleaning Procedure - Plug

1. Turn the fuel tank supply valve off.

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

Heed the gasoline warnings found on page 34.

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

4. Wipe off residue from plug and reinstall with clamps. Continue until all the traps have been emptied.

Cleaning Procedure - Nipple

1. Turn the fuel tank supply valve off.

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

3. Slide the clamp (1) away from the nipple (3) and remove the nipple. Empty the tube and reinstall. Continue until all the traps have been emptied.

MAINTENANCE

Fuel Filter/Fuel Lines

CAUTION:

The fuel filter (3 - external fuel filter) (4 - in-tank fuel filter) and fuel lines should be inspected regularly. Special attention should be given to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds can occur.

Oil Filter

The oil filter (5) is of a special design and must not be substituted. This filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 2000 miles (3200 km).

NOTE: The direction of the arrows indicates the direction of the flow through the filters.

NOTE: After changing the oil filter, the oil injection system must be bled of all trapped air. See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you.

The only oil recommended for this system is Polaris brand oil.

MAINTENANCE

General Carburetor Information

The number size stamped in the end ofthe mainjet indicatesthe jet size which was installed at the time of manufacture.

The installed main jet is not necessarily correct for your elevation.

It is the Polaris dealer’s responsibility to ensure that the correct main jets are installed in each machine for your area of operation.

WARNING

Carburetor adjustments should be performed only by a knowledgeable service technician at a Polaris servicing dealer using the proper tools, procedures and specifications.

Carburetor Adjustments

Proper carburetor adjustments include the following:

D Carburetor component changes for specific altitude and ambient temperatures; D Choke adjustment and synchronization; D Air screw settings, if applicable; D Idle RPM adjustments; D Equalizing air flow at idle; D Equalizing air flow at off idle; D Throttle safety switch checks and servicing; D Throttle block to throttle flipper clearance adjustment; and D Oil pump lever and cable adjustment, where applicable.

The frequency at which the carburetorsare synchronized or balanced is important. Properlyadjustedcarburetors can greatly improve engineperformance, fuel economy, engine life and reliability.

Improperlyadjusted or unsynchronized carburetors can lead to one or more of the following:

D Hard starting. D Poor idle. D Overheated pistons and cylinder walls. D Plug fouling. D Poor engine response to various throttle valve openings.

MAINTENANCE

ACCS

1. Air Box

2. Vent Line Attachment

3. ACCS Valve

Some models are equipped with the PolarisACCS (Altitude Compensating Carburetor System). The ACCS is designed to compensate automatically for changes in altitude without having to change carburetorjets. See your dealer for ACCS service or adjustment.

MAINTENANCE

Carburetor Protection During Off Season Storage

Whenever the machine is stored for a period of more than 60 days it is highly recommended that the engine be fogged with Polaris PN 2870791. Follow the engine fogging instructions provided on the can. See pages 85-86 for more complete information about storing your machine during the off season.

When preparing your snowmobile for off season storage we recommend that you add a fuel conditioner/stabilizer or Premium Carbon Clean (2871326) to the fuel tank. Follow the instructions on the can. Run the engine for five minutes to get additives through the entire fuel system. Then top off with fresh fuel.

If stabilizer is not used, the carburetors should be drained by removing the water trap drain plugs. Catch fuel in a container or shop cloth. Reinstall plugs securely. Observe all fire safety rules when draining carburetors. See gasoline warnings on page 34.

CAUTION:

Using lower than the recommended octane fuels or operating with obstructed fuel systems will lead to costly engine damage.

Exhaust System

At approximately 2000 miles (3200 km) it is a good idea to check the exhaust system for wear or damage. Toinspect, allow engine and exhaust system to coolcompletely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

WARNING

Exhaust system temperatures can exceed 900° F (500° C). Serious burns may occur if this inspection is performed without allowing adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

MAINTENANCE

Engine Cooling - Liquid Cooled Models

The cooling system on the liquid cooled Indy consists of the following major components: recovery tank, water pump, cylinders,heads, inlet and outlet manifolds, pressurecap and heat exchangers. The heatexchangers are located beneath the running boards and front close-off panel in front of the drive shaft and/or under the seat. Coolantis pumped through the cylinders,heads,and manifolds. Thecoolant is then pumped through the heat exchangers, where it is cooled as snow comes in contact with the fins on each exchanger. The “cooled down” fluid then returns to the water pump and is re-circulated.

Coolant Mixture

The coolant supplied in the system is a 50-50 mixture of ethylene-glycol and distilled water. This mixture will provide protection against freezing at temperatures down to -34° F (-37° C). If greater protection against freezing is required, the percentage of antifreeze to water may be increased. Use Premium 60/40 anti-freeze coolant. Never exceed a 60% antifreeze, 40% water mixture. Contact you dealer if greater protection is required.

NOTE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by a switch installed into the engine coolant system. If the engine coolant reaches acertaintemperature, depending on the model, the switch completes a circuit which turns the light on.

If you must drive the machine back to your starting point, drive slowly and stop frequently to allow normal cool down of the engine. Contact your dealer.

Coolant Level

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are: the coolant tank or overflow tank, engine filler neck, pressure cap (in some models), and connecting hoses.

As coolant operating temperature increases, the expanding excess coolant is forced out of the engine,past the pressure cap (if applicable), and into the overflow tank. As engine coolant temperature decreases, this contracting coolant is drawn back up from the tank, past the pressure cap or filter and check valve, and back into the engine.

CAUTION:

The coolant reservoir or surge tank must be maintained betweenthe minimumand maximum levels to prevent overheating and serious engine damage. Some models, maintain coolant level at the “full cold” line on the coolant tank with the engine cold.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold.

MAINTENANCE

Bleeding the Cooling System

WARNING

Never bleed the cooling system when the engine is hot. Severe personal injury could result from steam or hot liquid. Never remove the pressure cap (1) when the engine is warm or hot. If the pressure cap is to be removed, the engine must be cool.

Use of a non-standard pressure cap will not allow the recovery system to functionproperly. If the cap should need replacement contact your dealer for the correct replacement part and pressure rating.

Recovery System Models

If the coolant level becomes low in the recovery tank, the system should be bled of any trapped air using the following procedure:

1. Fill the recovery tank with coolant to the maximum indicated mark.

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

3. With pressure cap removed, add coolant and fill to the top of the filler neck.

4. Install the pressure cap with the lever lock up in its release position.

5. Run the engine at slow (600 RPM) fortwo tothree minutes. This will purge the system of trapped air.

6. Close the lever lock and check recovery tank fluid level.

CAUTION:

Most cooling systems are equipped with a filter (2) which should be periodically inspected or replaced. If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result.

MAINTENANCE

SurgeTankModels

1. Remove the pressure cap from the recovery tank and fill with properly mixed coolant to the maximum indicated mark.

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

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

4. Fill the recovery tank back to the maximum indicated mark.

5. Start the engine and run at a fast idle for two to three minutes. Occasionally loosen the bleed screw to purge any trapped air in the system.

6. Shut off engine and check the recovery tank level. Fill as required.

7. Feel the heat exchangers under the running boards. If the system is bled properly, they willbe warm to the touch. If they arenot,repeat step four and lift the front of the machine slightly to assist in the bleeding.

Throttle Cable Lubrication

With the engine off, lubricate the throttle cable occasionally with Polaris Cable Lubricant (PN 2870510). Turn the handlebars to the left and lubricate liberally as shown.

Choke and Cable Lubrication

Lubricate the choke slide and cables occasionally as shown with Polaris Cable Lubricant(PN2870510). Operate the choke intermittently before turning the machine off. This draws moisture out of the choke plunger area and reduces thepossibility of the choke becoming frozen.

MAINTENANCE

Chaincase Oil Level

The drive chain is continuously immersed in oil. Proper oil level is determined by checking the level on the dipstick (C) with machine placed on a level surface. The oil level should be between the “safe” marks on the dipstick. Add oil through dipstick opening to maintain proper level. Use Polaris chaincase oil (PN 2871280).

Do not overfill.

NOTE: Clean the magnetic plug (D) every 500 miles (800 km) and whenever checking or changing lubricant.

CAUTION:

Do not mix or use other types of lubricant. Excessive wear to chain, sprocketsand bearings will result.

It is the owner’s responsibility to maintain proper lubrication of the chaincase.

Drive Chain Tension

To obtain correct chain tension:

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

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

3. Finger tighten the adjuster bolt (B) until it can no longer be adjusted by hand.

4. Back off the adjusterbolt by 1/4 turn.

5. Tighten the jam nut while holding the adjuster bolt.

6. The chain is now tensioned. Release the brake lever lock.

MAINTENANCE

Gearcase Oil Level (WideTrak Models)

Using Polaris Chaincase Oil (PN

2871281), maintain the proper oil level. Proper oil level is determined by checking the level on the dipstick (A) with machine placed on a level surface. The oil level should be between the “safe” marks on the dipstick. Add oil through dipstick opening to maintain proper level. Do not overfill.

NOTE: Clean the magnetic plug (B) every 500 miles (800 km) and whenever checking or changing lubricant.

CAUTION:

Do not mix or use other types of lubricant. Excessive wear to chain, sprockets and bearings will result.

It is the owner’s responsibility to maintain properlubrication of the gearcase.

MAINTENANCE

Brake Inspection

The brake lever reserve should be inspected frequently. Measure the clearance between the lever and handlebar grip. Inspection should be made with the lever firmly depressed. Lever reserve (A) should be no less than 1/2″ (1.3 cm).

Replacement of brake pads will be necessary when the brake pad material is thinner than the backing plate approximately (1/16″). A kit is available for replacing brake pads. See your dealer.

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material (Replace when thickness is less than 1/16″.

Excessive Lever Travel

The snowmobile’s hydraulic brakes are self-adjusting. If excessive brake pad clearance should develop, the machine should be returnedto an authorizedPolaris dealer for inspection and adjustment.

MAINTENANCE

Replenishing Brake Fluid

CAUTION:

Brake fluid is a hazardous material. Contact with decals, paint, and many plastics will cause damage. Use proper precautions when handling brake fluid.

Remove brake fluid master cylinder reservoir cover. Add Polaris brake fluid (PN

2870990) as required to bring the level up to the top of the fluid level mark on the inside of the reservoir. The proper fluid level is 1/4-5/16″ (.6-.8 cm) below the lip of the reservoir opening on most models.

NOTE: On some models, the brake fluid level can be seen through a plasticsight glass in the brake reservoir. If the fluid is sufficient, the sightglass will be black. If the sight glass is any color other than black, you will need to add brake fluid.

On all models, frequently check the reservoir to be sure it contains the correct amount of fluid.

Use only Polaris DOT 3 high temperature brake fluid (PN 2870990). Polaris brake fluidissoldin12oz.bottles.

WARNING

Do not over fill the master cylinder. Fluid expansion could cause brakes to lock, resultingin serious injury or death. Once a bottleof brakefluidis opened, use what is necessary and discard the rest. Do not store or use a partialbottleof brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury.

Dirt and debris should be kept off the master cylinder cover. The cover has vent slits to allow for diaphragm movement. If these ventsbecome plugged, movement of brake fluid below the diaphragm may be restricted, altering brake function.

MAINTENANCE

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause a springyor spongy brake leveraction. Bleeding is necessary to remove air from the system. Refer to illustration on page

69.

1. Remove brake fluid master cylinder reservoir cover and gasket.

CAUTION:

Brake fluid is a hazardous material. Contact with decals, paint, and many plastics will cause damage. Use proper precautions when handling brake fluid.

2. Fill the master cylinder reservoir (B) and replace gasket and cover. Keep the fluid level 1/4-5/16″ (.6-.8 cm) below lip of reservoir opening.

3. Fill the master cylinder reservoir (B) and replace gasket and cover. Keep the fluid level between the max and min marks on the side of the reservoir.

WARNING

Do not over fill the master cylinder. Fluid expansion could cause brakes to lock, resulting in serious injury or death.

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

WARNING

Never re-use brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, leading to early brake fade and the possibility of serious injury.

5. Squeeze brake lever a full stroke. Then unscrew bleedervalve 3/4 of a turnto release air.

6. Close bleeder valve and release brake lever.

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

7. Re-fill reservoir to proper level after bleeding operation. See Replenishing Brake Fluid on page 70. Do not overfill the master cylinder.

8. Replace gasket and cover.

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

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 severe injury or death.

When traveling in long downhill stretches remember to use a pumping brake action. Riding the brakes can cause the brake system to overheat,resulting inbrake failure.

MAINTENANCE

Brake Adjustment - Mechanical Brakes

Ifexcessive brake lever to brake block clearance is evident, the brake cable orcaliper should be adjusted using the following methods. When adjustingcalipers,adjust caliper adjuster bolt only. Do not adjust cable or cable sleeve length.

WARNING

Improperbrake adjustmentcould result in brake failure which could resultin severe injury or death.

Cable Adjustment

1. Make sure floating parts move freely and all parts are mounted securely. Tighten hardware as required.

2. Check actuator linkage to ensure there is adequate freedom of movement for positive brake operation.

3. Loosen lock nuts (A).

4. To increase brake lever free play, turn nuts counterclockwise to move cable (B) down in bracket. To decrease lever free play move cable up in bracket. Tighten lock nuts.

5. If cable adjuster has reached maximum, the lever arm can be re-indexed twice before brakepads require replacement. When pads are replaced, brake lever arm must be re-indexed to obtain proper freeplay. Brake lever free play should be 1/4 - 3/8″ (6-10 mm).

6. Loosen lock nuts andturn counterclockwise(as viewedfromthe top) to obtain the maximum amount of cable freeplay. Straighten tab on tab washer and loosen bolt enough to disengage actuator lever spline.

1/4-3/8″ (6-10 mm)

MAINTENANCE

Cable Adjustment (Cont.)

7. Slip long leg of lever spring (D) off caliper and rotate to the side.

8. Rotate lever (E) one tooth in the direction opposite the actuation direction and tighten bolt. Make sure spline teeth are properly engaged.

9. Bend up a tab (C)aligningwithone of the bolt head flatsto preventbolt rotation.

10. Return the spring to its original position on the caliper. Both lever and linkage must be free to return to original position.

11. Perform steps 3. and 4. to adjust lever freeplay.

12. Verify proper brake operation. Disc should rotate freely without drag.

13. Check disc surface condition.

Mechanical Brakes

Brake Lever Travel

Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance B should be no more than 3/4″ (1.9 cm).

Excessive travel indicates a need to adjust the brake cable adjuster. Refer to the mechanical brake adjustment information on page 72.

MAINTENANCE

Brake Inspection

WARNING

Be certain brake pads do not drag on disc and brake lever travelis not excessive. Replacement of brake pads will be necessary when the brake pad material is thin-

ner than the backing plate approximately (1/16″). A kit is available for replacing brake pads. See your dealer.

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material (Replace when thickness is less than 1/16″.

MAINTENANCE

Headlight Adjustment

The headlight can be adjusted for vertical aim using the following procedure:

1. Place snowmobile on a level surface with headlight approximately 25’ (7.6m) from a wall.

2. Measure distance from floor to center of headlight and make a mark on the wall.

3. Start engine and turn headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight beam should be aimed 2″ (5.1 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included on the seat.

5. On evolved models, turn the adjustment knob (B) located inside the hood just below the headlamp opening. Turn knob in or out as needed for proper aim. On aggressive models, insert a Phillips screwdriver into the access hole (C) on the top of the instrument housing and turning the screw until correct adjustment is achieved.

25’ (7.6 m)

Lamp Center Height

2″ (5.1 cm)

MAINTENANCE

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

due, causing a hot spot which will shorten the life of the lamp.

Removing Halogen Bulbs - Low Beam

1. Pinch ends of the spring (1) together and liftuntilit releases from the spring retainer.

2. Lift spring carefully around wire harness (2) and flip to outside of housing.

3. With the wire harness attached tothe bulb (3), withdraw bulb fromhousing.

4. Grasp bulb by metal base and carefully separate bulb from harness.

Installing the Bulb

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 harness.

4. Squeeze spring together until it is over the spring retainer and release.

5. Verify headlight aim.

Removing Halogen Bulbs - High Beam

1. Remove the wire harness

2. Gasp the bulb firmly and twist it 1/2 turn counterclockwise.

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten thelifeofthelamp.

3. Remove the bulb from housing and replace with new bulb.

4. Place the bulb and housing back inside the hole and turn the housing 1/2turnclockwisetolockintoplace.

5. Reinstall the wire harness to the housing.

MAINTENANCE

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

due, causing a hot spot which will shorten the life of the lamp.

Removing the Side Bulbs

1. Disconnect terminal from back of bulb.

2. Turn bulb assembly 1/4 turn to right and withdraw from housing.

Installing the Side Bulbs

1. Hold bulb assembly by plastic base and plug into wire terminal.

2. Insert bulb assembly into housing.

3. Turn bulb assembly 1/4 turn to left to secure in housing.

4. Verify headlight operation.

Wrap Around Taillight Bulb Replacement

1. Remove Phillips screws from taillight lens (A).

2. Working from front to back, carefully pry lens away from seal and remove lens.

3. Pull bulb(s) (B) straight out from socket and insert new bulb.

4. Reinstall lens.

MAINTENANCE

Handlebar Adjustment - All Other Models

Your snowmobile has handlebars which may be adjusted for your personal fit.

1. Remove handlebar cover and foam.

2. Usinga7/16″ (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or rightfor access to back nuts.

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

4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (1.5-1.8 kg/m).

5. Replace handlebar cover and foam.

MAINTENANCE

Backrest Adjustment

The passenger backrest on some models is adjustable. To move the backrest forward or backward, lift the adjustment lever on the left side (A).

To lengthen or shorten the backrest cable, lift the cable until spring tension is felt and lock the jamb nut. When adjusting the backrest from a passenger position to a single rider position, rotatethebackrestcushion adjustmentknobs (B) until the properangle isreached. The grab bars have five height adjustments. To raise orlowerthe grab bar,remove the grab bar adjuster knob (C),position the grab bar atthe desired height, and reinstall the knob. Some models are also equipped with passenger handwarmers. The switch (D), located under the left hand wind deflector, has three settings: High, Off, and Low.

MAINTENANCE

Drive Belt

WARNING

Periodicallycheck the condition and tensionof thedrive belt. Always carry a spare belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil base cleaner such as isopropyl alcohol.

To ensure satisfactory belt life, install belts so they operate in the same direction of rotation. Position the identification numbers so that you can read them. This will keep the belt rotating in the same direction.

For improved drive away during extreme cold temperatures, remove the belt and warm it up to room temperature. Reinstall it before starting the vehicle.

Belt Removal - A

1. Be sure key switch is off and engine has come to a complete stop. Remove the retaining knob or pin and open the clutch guard.

2. Apply brake (or lock parking brake if so equipped).

3. Grasp belt firmly midway between clutches and pull upward and rearward. Remove the belt.

Belt Installation - B

1. Drop the drive belt over the drive clutch and pull back the slack. Numbers should be readable from right side of unit.

2. Turn the driven clutch moveable sheave clockwise while at the same time 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. Once installed,besure to work the belt to the outer edge of the sheave. Be sure to release parkingbrakeifapplied.

4. Close the clutch guard and reinstall the retaining knob or pin.

B.1

B.3

A.3

MAINTENANCE

Clutch System

Do not lubricate clutch bushings. The bushings in the weights and rollers ofPolaris clutches are made ofa material which may be damaged if lubricated. Clean clutch sheaves periodically to maintain optimum performance.

WARNING

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

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

Clutch Alignment and Offset

The primary drive belt is a very important part of the drive train. Proper adjustment of the two clutches (torque converter assembly) is necessary to obtain proper belt life. The information on this page is most important in maintaining proper tolerances. If you desire more information, consult your dealer.

The recommended offset between the drive and driven clutches with the belt removed is found on the Owner’s Manual Specification Supplement.

Clutch center distance and alignment are crucial in maintaining optimum performance. The drive belt is a very important part of the drive system. Belt to sheave clearance in the drive clutch should be kept at a minimum. With a new belt, the least amount of clearance will provide the best throttle response. See your dealer for adjustments. 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. beltsbe used. Other beltsmay match the dimensions,but can drastically change the shiftpattern,resulting in poor performance characteristics.

NOTE: A worn belt will continue to function, but will not deliver maximum performance. Always carry a spare belt in case of an emergency. Belt removal and installation are covered on page 80.

Clutch Alignment

See Owner’s Manual Specification Supplement for specification

MAINTENANCE

Clutch Center Distance

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

Place a straight edge on the belt and apply downward pressure while measuring at the point shown.

The recommended center distance for your machine can be found on the Owner’s Manual Specification Supplement.

Due to tolerances in belt length, it may be necessary for your dealer to make minoradjustmentsinthe driven clutch to achieve correct belt tension.

Belt Deflection Adjustment (P-85 System)

Adjustment can be done on P-85 clutches without removing the clutch from the jackshaft.

1. Pull belt into driven clutch to slightly open sheaves.

2. Loosen the three bolts on the adjustment cam.

3. To reduce distance between sheaves, turn cam counterclockwise. Torque bolts to 10 ft. lbs. (1.4 kg/m)

NOTE: If your model has a P-90 clutch, any adjustments must be performed by your dealer.

Belt Tension

Straight Edge

Measure at this point

MAINTENANCE

Torque Stop

If your machine is equipped with a torque stop, periodically check torque stop clearance. Before this procedure it will be necessary to ensure the clutches are properly aligned. The torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case. Adjust if necessary and lock jam nut.

Reverse Kit Maintenance

If your machine is equipped with reverse or if you have a reverse kit installed, it is especially important to maintain track tension as specified on page 89.

WARNING

If specified track tension is not maintainedsevere damage to the machine may occur,which can result in loss of vehicle control. Loss of control can result in severe personal injury or death.

D Never attempt to shift into reverse while machine is moving. D Allow engine to reach idle speed before attempting to shift into or out of reverse.

CAUTION:

If machine has not come to a complete stop before shifting, damage will occur to chaincase or transmission.

If you have had a reverse kit installed on your snowmobile, some maintenance will be required. Follow these recommendations:

Chain Tension

Maintain the proper chain tension. See page 67.

Oil Level

Maintain the oil level between the safe marks on the dipstick.

Oil Change

Change the oil annually.

MAINTENANCE

Reverse Operation

WARNING

This snowmobile is capable of excessive reverse speed! Reverse operation can be dangerous even at moderate speeds. Steering control becomes difficult in reverse. Misuse of reverse can result in serious injury or death.

The transmission may not always be in the gear indicated by the shift lever. Apply the throttle slowly until the correct gear is assured.

Make sure the shift lever is shifted completely into forwardor reverse position. Do not force the shift lever into reverse if resistance is felt.

The gears may not always be aligned for shifting into reverse. Forcing the lever may cause the cable to bend. If resistance is felt, apply the throttle to move the gears to a different position and try to shift again.

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

MAINTENANCE

Extended Storage

Offseason or extended storage of yoursnowmobilerequiresyou to take preventative measures to aid against deterioration and to prolong the useful life of many components.

Cleaning and Preservation of Hood, Chassis, and Trim

Proper storage starts by cleaning, washing, and waxing the hood, chassis, upholstery, and plastic parts. Clean and touch up with paint any rusted or bare metal surfaces. Be sure that corrosivesalt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint).

The machine should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover. Plastic tarp can cause condensation to form and damage some snowmobile components.

Controls and Linkage

All bushings, spindle shafts, and tie rod ends should be coated with a light coat of oil or grease. Throttle controls and cables should be lubricated with Polaris cable lubricant (PN 2870510). Force a small amount of lubricant down the cable.

Bearings

To prevent corrosion which willdestroy the bearings, always grease jackshaftand drive shaft clutch side bearings with a high quality bearing grease. See page 52.

Electrical Connections

Separate electrical connector blocks and clean corrosive build up from connectors. Lubricate or pack connector blocks with dielectric grease (PN 2871044) and re-connect. Replace worn or frayedelectrical wireand connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust.

Clutch and Drive System

Remove drive belt and store in cool dry location. Lubricate sheave faces of drive and driven clutches with a lightcoat ofoil orPolarisCableLubricant(PN2870510). Do not lubricate clutch components except driven clutch shaftbushing as outlined in Snow Repair Manual.

Battery

Battery must be prepared and maintained as outlined on page 45.

Front Suspension

To minimize fatigue on the front shocks and springs, it is recommended that the front end of the machine be safely blocked off the ground, removing tension from the shocks and springs.

MAINTENANCE

Engine and Carburetor

Proper off season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage.

Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quality.

D When preparing your snowmobile for off-season storage we recommend that

you add fuel conditioner/stabilizer or Premium Carbon Clean ( PN 2871326) to the fuel tank. Follow the instructionson the can. Run the engine for five minutes to get additives through the entire fuel system. Then top off the tank with fresh fuel.

D Fog the engine with Polaris Fogging Oil (PN 2870791). This is available from

your Polaris dealer. Follow the recommended procedures indicated on the can.

D If stabilizer is not used the carburetors should be drained by removing the the

drain plugs or nipples. Refer to page 59 forprocedure. Catch fuel in a container or shop cloth. Reinstall and tighten drainplugs securely. Observe all fire safety rules when draining carburetors. See gasoline warning on page 34.

Engine and Carburetor

Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure:

1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage.

2. Securely supportthe frontof thesnowmobile with a jack stand so the engine is tilted rearward.

3. Remove the spark plug(s).

4. Rotate the engine slowly,watching thepiston untilit is atBDC - lowest position in the cylinder. On twin cylinder models the opposite piston will be up.

5. Pour approximately two ounces of Polaris injector oil into the spark plug hole.

6. Wait one to two minutes and perform steps 4-6. on remaining cylinders.

7. Replace the spark plugs and set machine on floor

NOTE: This procedure is performed best when the front of the machine is elevated and the engine is tilted rearward.

Track and Suspension

Under normal conditions moderate track tension should be maintained during summer storage. The rear of the machine should be supported off the ground to allow free hanging of the track.

HINT: For easier starting after extended storage, add Polaris Premium 2 cycle lubricant to the fuel in the tank at a 40:1 ratio and run the engine for three to fiveminutes before storage. This willlubricate the fuel pump diaphragm to keep it flexible and help prevent loss of prime.

MAINTENANCE

Transporting the Snowmobile

Whenever the snowmobile is transported the following measures should be taken:

1. Turnthefuelvalveto“Off”.

2. Be certain the fuel cap and oil cap are installed correctly.

3. Always tie the snowmobile to the transporting unit securely using suitable straps.

MAINTENANCE

Fall Tune Up

To obtain maximum performance and use from your snowmobile, we encourage you to arrange fora fall service tune-up with your Polarisdealer. He has an experienced and trained service technician who is interested in keeping your machine in peak operating condition.

Towing

If a situationarises requiring the snowmobile to be towed by another snowmobile, attach the tow rope to the spindles, not the ski loops.

WARNING

Always remove the drivebeltfroma disabled snowmobile before towing to prevent serious damage to the engine and drive system.

Tool Kit

To help you performemergency and routine maintenance, a tool kitis includedwith your machine. Items included in the kit are:

D Tubular Socket

D Phillips Screwdriver

D Emergency Start Strap

D Tubular Socket Handle

D Wrench

D Shielded screwdriver (only with

models that have indy select or AFX shocks)

Remember, always keep tools with the machine.

NOTE: Other tools are also neces-

sary to perform maintenance work. They are called out throughout this manual.

If necessary a replacementtoolkitmay be purchased fromyour Polaris dealer. Ask for PN 3083227.

For Your Protection

For your added protection it is a good idea to carry the following items with your snowmobile at all times:

S Spare Drive Belt S Extra Set of Spark Plugs S Tow Rope S Extra Oil S Fuel Deicer S Winter Survival Kit S Trail Map S Owner’s Manual S First Aid Kit

MAINTENANCE

Track Tension Data

Suspension

(Refer to Specifi-

cation Supple-

ment for type)

Weight Measurement

Location

Measurement

XTRA 12 121″ none 2″ behind rail

bumper

1/2″ (1.27 cm)

free hanging

XTRA 12 133″ none 16″ ahead of rear

idler shaft

1-1 1/8″ (2.54 -

2.86 cm)

free hanging

XTRA 10 121″

and 133″

10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

3/8 - 1/2″ (1 - 1.3

cm)

WideTrak Type 10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

3/4 - 1″ (1.9 - 2.5

cm)

XTRA Lite 121″,

133″ and 136″

10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

3/8 - 1/2″ (1 - 1.3

cm)

XL 136″ 10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

3/8 - 1/2″ (1 - 1.3 cm)

WARNING

When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts to avoid serious personal injury. Do not perform track measurement or adjustments with engine running.

MAINTENANCE

Tra ck Te nsi on

Track adjustment is critical for proper handling. Always maintain correct tension and alignment.

Tension adjustments should be made only after the track is warmed up and limber.

1. Turn the machine off.

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

3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of the rear idler wheel.

NOTE: Measure at the point where the weight is hanging.

4. Check for specified slack between the wear surface of the track clip and the plastic hi-fax (C).

If the track needs adjustment:

5. Loosen rear idler shaft bolt (D).

6. Loosen locknuts (A) (except on models with Xtra Lite suspension).

7. Tightenor loosenthe trackadjusting screws (B) as necessary to provide equal adjustment on both sides of the track.

8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new.

9. Start machine and slowly rotate the track at least five revolutions,let the track stop rotating by itself (do not apply brakes).

10. Check track alignment (side to side) by comparing the distance from the guide clip to Hi-fax on both sides. Readjust until centered.

11. Tighten Locknuts (A)

12. Tighten Idler Shaft Bolt (D)

A D

Track

Hi-fax

XTRA 10

WIDETRAK

weight

MAINTENANCE

10 lb. Weight (4.5 kg)

Track

Hi-fax

XTRA LITE

2″

121″ =1/2″ 133″ =1-11/8″ measured 16″ahead of rear idler center

Rail bumper

Rear idler shaft bolt

Track

Hi-fax

Track adjusting bolt

XTRA 12

MAINTENANCE

WARNING

When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.

Track Alignment

A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. NOTE: If excessive hi-fax wear occurs due to poor snow conditions, additional wheel kits are available. Consult your dealer.

1. Safely support the rear of the machine with the track off the ground.

2. Starttheengine and apply a small amount of throttleuntilthe track turns slowly at least five complete revolutions. Stop the engine.

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 left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, be sure to tighten locknuts and idler shaft bolts. Torqueto 35-40 ft. lbs. (4.8-5.5 kg/m).

5. Repeat step 2 to verify proper alignment.

Looking through track window, make sure the rails are evenly spaced on each side.

Rail

Hi-fax

MAINTENANCE

Track Warm Up

When storing your snowmobile outside overnight, it is recommended that the track be warmed up prior to driving the snowmobile. This reduces belt and drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine and abruptly en- gage the clutch. Allow the track to turn for a short time. Release the throttle, apply the brakes and shut the engine off prior to lowering it to the ground.

WARNING

Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.

MAINTENANCE

Track Inspection

WARNING

Never make this maintenance check with the engine running,as serious personalinjurycan result.

Using a hoist, safely lift and support the rearof the snowmobile off the ground. Rotate the track by hand to check for any possible damage.

To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. The three most common places where breakage occurs are shown in the illustration.

If any rod damage is found, the track should be replaced.

WARNING

Broken track rods are a serious hazard, since they can cause a rotating track to come off the machine. Never operate or rotate a torn or damaged track under power. Serious personal injury or death may occur.

21312

Track window

Lug

MAINTENANCE

Track Lubrication

WARNING

Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between hi-fax and track guide clips. Examples of marginal lubrication would include lakes without snow cover, icy trails and no-snow conditions.

The slide rail is designed to operate in conditions with adequate snow cover in order to provide sufficient lubrication. Excessive wear indicates insufficient lubrication. New hi-fax can cause faster heat build up in limited lubrication than used hifax, resulting in excessive wear. NOTE: If excessive hi-fax wear occurs due to poor snow conditions, additional wheel kits are available. Consult your dealer.

CAUTION:

Track damage or failure caused by operation on ice or poor lubrication conditions will void the track warranty.

Traction Products

NOTE: Tracks with deep lug design cannot be studded.

CAUTION:

Polaris does not

recommend the use of traction products on WideTrak snowmo-

biles.

CAUTION:

If traction products are to be added to the track, wear strips must be installed in the tunnel to avoid excessive wear. This applies to all models.

Shims should never be added to the wear strip or track damage will result due to lack of clearance between upper carrier wheels and track.

Use of studs greater than 1″ (2.5 cm) on machines equipped with center coolers will result in center cooler damage, or damage to tunnel.

Always inspect for track damage before using the vehicle. Use of tractionproducts such as studs, ice growsers,paddles, etc. will increase the possibility of track damage and/or failure, which could cause loss of control resulting in severe injury or death.

In the event you wish toinstallstuds, carbides or ice growsers,contact yourPolaris dealer for advice.

Track damage or failure resulting from improper or excessive stud installation voids any track warranty, as does installation of the Hooker™ stud system.

Polaris Universal Snow (2000) Owner's Safety And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual