Polaris Universal Snowmobiles User Manual

2003 SNOWMOBILES

Universal Owner's Maintenance

and Safety Manual

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

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

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

What’s the hottest thing on snow?

Our new web site. It’s designed just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

-NOTES-

WELCOME

Thank you for purchasing a Polaris snowmobile, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.

We believe Polaris sets 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’ve ever produced.

Follow the instructions and recommendations in this Owner’s Manual for safe and enjoyable operation of your vehicle. Your Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

Your Polaris snowmobile dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris and Polaris The Way Out are registered trademarks of P olaris Industries Inc.

TABLE OF CONTENTS

Section 1 - Introduction 5 - 9..................

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

Section 2 - Safety 1 1 - 33.....................

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

Section 3 - Features and Controls 36 - 41......

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

Section 4 - The Perfect Fit 43 - 74..............

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

Section 5 - Getting Ready to Ride 75 - 81.......

This section explains procedures that must be performed before riding.

Section 6 - Operation 83 - 103.................

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

Section 7 - Maintenance 105 - 165.............

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

Section 8 - Troubleshooting 167 - 175..........

This section is a quick reference guide to solving problems.

Section 9 - Warranty 178 - 183.................

This section contains specific warranty information.

SECTION 1 - INTRODUCTION

Important Notes for Drivers 6.................

Preservation Of The Environment 7 - 8........

Vehicle Identification Numbers 9..............

Section 1 contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner’s Manual. It also defines your role in protecting and respecting your environment while experiencing The Way Out.

INTRODUCTION

Important Notes For Owners And Drivers

n After reading this manual, store it in the snowmobile for

convenient reference. It should remain with the snowmobile when sold.

n This manual contains the latest information at the time of printing.

We reserve the right to make product changes and improvements without notice.

n The illustrations and photos used in this manual are general

representations. Your model may differ.

n Follow the maintenance program outlined in this manual.

Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

n You and your dealer must complete the registration form included

with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

n Protect and preserve your right to ride by joining your local trail

riding clubs.

INTRODUCTION

Preservation Of The Environment

Please operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

Polaris snowmobiles are engineered to conform t o these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

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

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

INTRODUCTION

Preservation Of The Environment

Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs t hat encourage protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and do your part to preserve and protect our environment.

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

INTRODUCTION

Vehicle Identification Numbers

Please record your snowmobile identification numbers below for future reference:

Tunnel VIN (lower right side of the tunnel)

Engine Serial Number (right front side of engine crankcase)

Remove the spare key and store it in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and mating it with your existing key.

The VIN and engine serial numbers are necessary for model identification when registering your vehicle and obtaining insurance, or when replacement parts are required. If your snowmobile is stolen, these numbers are essential to its recovery and identification.

Dealer Imprint

-NOTES-

SECTION 2 - SAFETY

Operator Safety 12 - 27.......................

Safety Decals and Locations 28 - 33...........

Section 2 describes safe vehicle operation and identifies warning decals and their locations.

SAFETY

Operator Safety

The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their m eanings before reading the manual.

The safety alert symbol, on your snowmobile or in this manual, alerts you to the potential for personal injury.

WARNING

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

CAUTION

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

CAUTION

Indicates a situation that may result in damage to the machine.

NOTE

“NOTE:” will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

Polaris produces high performance snowmobiles capable of traveling at high speeds. Extra caution must be observed to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. We strongly recommend that the operator check major and vital safety components before every ride.

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

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

SAFETY

Operator Safety

Stay Away From Moving Parts

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.

We recommend having your dealer perform track service and alignment procedures.

Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track.

WARNING

Stop the engine before attempting adjustments. If contact is made with fingers or clothing, the moving parts of an engine can cause serious injury.

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

SAFETY

Operator Safety

Be Seated and in Position to Control the Vehicle

WARNING

Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle.

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably positioned for proper throttle, brake, and steering control.

WARNING

Use of a backrest may hinder your weight shifting ability. This could affect your ability to control this rider-active vehicle in certain extreme driving situations.

Be Prepared fo r the Unexpected

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

SAFETY

Operator Safety

Do Not Overload Cargo Carrier

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

WARNING

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

Always Wear Clothing Designed f or Snowmobiling

WARNING

Loose clothing or long scarves may easily become entangled in moving parts and cause serious personal injury .

Always wear an approved helmet and eye protection.

Be aware of the weather forecast and especially the wind chill. A table is provided on page 26 for your reference. To better enjoy your ride, be prepared, warm, and comfortable.

SAFETY

Operator Safety

Disabled Operators

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

Know the Limitations of the Machine and Yo ur Skills as a Driver

WARNING

High speed driving, especially at night, is dangerous and unwise and could result in serious personal injury or death.

Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.

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

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

SAFETY

Operator Safety

Know the Limitations of the Machine and Yo ur Skills as a Driver

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

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

Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you. Before riding your machine on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. You may drown if you and the snowmobile break through the ice.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.

SAFETY

Operator Safety

Ice and Snow Build -up

WARNING

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

Before driving, manually turn the skis to t he left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Snow screens and bib kits are available through your dealer to help reduce snow and ice build-up.

Operation on Hard -Packed Snow or Slippery Surfaces

WARNING

Driving on ice or hard-packed snow reduces steering and braking control, which may result in serious injury or death. Slow down and use caution.

Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death. Slow down to maintain control under these conditions.

It’s dangerous to drive on ice or other slippery surfaces. If it’s unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction. The chance of “spin-out” increases under these conditions.

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

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

Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.

If you must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and avoid possible roll-over.

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

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

SAFETY

Operator Safety

Riding Downhill

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

WARNING

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

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

Do Not Operate Engine With Clutch Guard Removed

The clutch guard is designed to protect the operator from metal parts if the clutch should fail. Although the chance of failure is extremely remote, don’t defeat the purpose of the guard by removing it. It’s provided for your safety.

Do Not Operate Engine With Drive Belt Removed

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

SAFETY

Operator Safety

Do Not Operate Engine With Intake Silencer or Filter Removed

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

Do Not Service Clutches You rself

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

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the machine into motion, but always operate within safety limits and, on 2-Up machines, with respect for a passenger. See page 84 for more detailed instructions on cold weather drive-away.

Machine Maneuverability

Control and maneuverability comes not only through the steering and skis, maximum control is achieved by shifting of body weight. Maneuverability will change for lighter operators or machines designed to carry a load or a passenger.

SAFETY

Operator Safety

Powder Snow Operation

Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F ), Polaris recommends closing the upper hood closure.

WARNING

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

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

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

CAUTION

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

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 106 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. See page 30 for decal location.

Driving 2-Up - Some Polaris snowmobiles are designed for two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. See page 30 for decal location.

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

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

SAFETY

Operator Safety

Responsible Driving

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

n A snowmobile depends on the rider’s body position for proper

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

n Before allowing someone else use your snowmobile, know the

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

n Don’t “jump” your snowmobile. Jumping may injure your back

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

n Be courteous to oncoming traffic by dimming your headlights and

reducing your speed. Your snowmobile is equipped with a high output headlamp system that may cause discomfort to operators of oncoming vehicles when on high beam.

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

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

n Don’t tempt anyone to steal your snowmobile or ride it without

permission. Remove the key from the ignition.

SAFETY

inMPH

tleAdde

ect

Clo

the

dPers

on)

LittleAddedEffectClothedPerson)

Operator Safety

Windchill/Temperature Ch arts

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

WIND CHILL CHART (°F)

Estimated Wind Speed

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

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

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

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

15 36 22 9 -5 -18 -36 -45 -58 -72 -85 -99 -11

20 32 18 4 -10 -25 -39 -53 -67 -82 -96 -110-12

25 30 16 0 -15 -29 -44 -59 -74 -88 -104-118-13

30 28 13 -2 -18 -33 -48 -63 -79 -94 -109-125-14

35 27 11 -4 -20 -35 -49 -67 -82 -98 -113-129-14

40 26 10 -6 -21 -37 -53 -69 -85 -100-116-132-14

Wind Speeds Greater

Than 40 MPH Have

Eff

Little Danger

(For Properly

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

Operator Safety

inKPH

)

WIND CHILL CHART (°C)

SAFETY

Estimated Wind Speed

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

dded E

ect

Actual Thermometer Reading (°C)

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

Equivalent Temperature (°C)

Little Danger

(For Properly

lothed Person

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

SAFETY

Safety Decals And Locations

NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed on the decal.

Clutch Cover Warning Decal - 1

This warning decal is found under the hood on the clutch cover:

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.

Airbox Warning Decal - 2

This warning decal is found under the hood on specific models:

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

Pressure Cap Warning Decal - 3

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

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

1, 2, 3

+ 159 hidden pages