Polaris Widetrack LX User Manual

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Pantone 426C

Widetrak LX

Snowmobile Owner's Manual

for Maintenance and Safety

WARNING

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

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

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Pantone 426C

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922310 Rev 02 Printed in USA

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

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

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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

Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2010 Widetrak LX Owner’s Manual P/N 9922310

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Features and Controls . . . . . . . . . . . . . . . . . . . 26

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 38

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 103

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 104

This section is a quick reference guide to solving general problems.

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 118

Record maintenance and service in the log for your reference and for future owners of the vehicle.

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold.

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

Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding clubs.

Some of the illustrations and photos used in this manual are general representations. Your model may differ.

INTRODUCTION

Preservation of the Environment

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

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

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

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

Air Pollution

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

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

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number: ___________________________________________________

Tunnel VIN: ____________________________________________________________ (lower right side of the tunnel)

Engine Serial Number: ___________________________________________________ (right front side of engine crankcase)

Key Number: ___________________________________________________________

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program outlined beginning on page 60 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. Always check major and vital safety components before every ride.

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

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

SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.

WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

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

WARNING! Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.

SAFETY

Operator Safety

Survival Preparation

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

Always carry the owner’s manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

Riding Position

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

WARNING! Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.

SAFETY

051039

0006.31

Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Clothing

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22.

WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.

SAFETY

Operator Safety

Cargo Overload

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

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills.

WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle.

Rider Capacity

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

Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A label on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. See page 23 for label location.

Snowmobiles 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 snowmobile 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

Excessive Speed

WARNING! High speed driving, especially at night, could result in serious injury

or death. Always reduce speed when driving at night or in inclement weather.

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. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your snowmobile travels. If your speed is 40 MPH, your snowmobile is traveling about 60 feet per second. If you look back for only two seconds, your snowmobile will travel about 120 feet. If your speed is 60 MPH, your snowmobile 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 snowmobile to a stop in the distance illuminated by the headlight.

SAFETY

Operator Safety

Driver Awareness

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

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your snowmobile 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 snowmobile on a frozen body of water, be sure the ice is thick enough to support the snowmobile 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.

SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped with a shovel, probe and avalanche beacon.

You don’t have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected. You may be riding on a flat slope or snow covered road, but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you. Always be aware of snow conditions above you as you travel in mountainous terrain.

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

For more information about avalanche training and avalanche conditions, contact local law enforcement in your area, or visit the American and Canadian online avalanche centers at www.avalanche.org.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, 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.

Driving on Slippery Surfaces

WARNING! Never attempt an abrupt change of direction when operating on

slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hardpacked snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.

SAFETY

Operator Safety

Driving on Slopes

WARNING! Climbing a hill or crossing the face of a slope may result in loss of

balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover.

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 snowmobile 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 snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the parking brake, and descend the hill carefully.

SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

Clutch Guard

Do not operate the engine with the clutch guard removed.

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

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed by your dealer.

CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine.

SAFETY

Operator Safety

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

NOTICE: Damage to the engine may occur if the intake silencer or filter are

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the snowmobile into motion, but always operate within safety limits and, on 2-up snowmobiles, with respect for a passenger.

Maneuverability

While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change for lighter operators or snowmobiles designed to carry a load or a passenger.

removed.

SAFETY

Operator Safety

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile.

WARNING! Inadequate cooling and lubrication will lead to overheating of the slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

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

SAFETY

Operator Safety

Driving Responsibly

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

• A snowmobile depends on the rider’s body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

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

• Don't "jump" your snowmobile over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and reducing your speed.

• When traveling in a group of snowmobiles, don’t tailgate (follow too closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile unattended.

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Wind

Speed

40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

MPH

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

5 3631251913 7 1 -5-11-16

10 34 27 21 15 9 3 -4 -10 -16

15 32 25 19 13 6 0 -7 -13

20 30 24 17 11 4 -2 -9 -15

25 29 23 16 9 3 -4 -11 -17

30 28 22 15 8 1 -5 -12

35 28 21 14 7 0 -7 -14

40 27 20 13 6 -1 -8 -15

45 26 19 12 5 -2 -9 -16

50 26 19 12 4 -3 -10 -17

55 25 18 11 4 -3 -11

60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (_F)

Equivalent Temperature (_F)

-20 -25 -30 -35 -40 -45

-22 -28 -34 -40 -46 -52 -57 -63

-22 -28 -35 -41 -47 -53 -59 -66 -72

-19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

30 min. 10 min. 5 min.

WIND CHILL CHART (°C)

Wind

Speed

5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

KPH

Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29

16 2 -2 -6 -10 -13 -17 -21 -24 -28

24 1 -3 -7 -11 -15 -19 -22 -26

32 0 -4 -8 -12 -16 -20 -24 -28

40 -1 -5 -9 -13 -17 -21 -25 -29

48 -1 -5 -9 -13 -18 -22 -26

56 -2 -6 -10 -14 -18 -22 -26

64 -2 -6 -10 -15 -19 -23 -27

72 -2 -7 -11 -15 -19 -23 -28

80 -3 -7 -11 -15 -20 -24 -28

88 -3 -7 -12 -16 -20 -24

96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (_C)

Equivalent Temperature (_C)

-32 -36 -39 -43 -46 -50 -53 -57

-32 -36 -39 -43 -47 -50 -54 -58 -62

-30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

30 min. 10 min. 5 min.

-31 -34 -37 -40 -43 -46

SAFETY

Safety Labels and Locations

Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile.

If any label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

Clutch Cover Warning

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

WARNING Do not operate engine with hood open. Do not attempt adjustment with engine running. Do not operate engine with this guard open. Never run engine with drive belt removed. Never service clutches yourself - see your dealer.

Air Box Warning

This warning label is found under the hood on applicable models:

CAUTION Do not operate above 40 mph with hood-to-air box foam removed

or engine failure will result.

Passenger Warning

Your Polaris Widetrak snowmobile is designed for the operator and one passenger. For more information on operating with a passenger, see Page 12.

WARNING This vehicle is designed for opera-

tor and ONE passenger

SAFETY

Safety Labels and Locations

Track/Seat Warning

The track/seat warning label is on the rear of the tunnel:

WARNING Stay clear of track. Do not sit on seat

back. Entanglement with the track or a fall from seat back may result in severe injury or death.

Reverse Warning

Polaris Widetrak snowmobile is equipped with standard reverse. The reverse warning label is located above the instrument housing.

WARNING Reverse operation, even at low

speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.

NOTE: For more information, see Owner's Manual.

SAFETY

Safety Labels and Locations

Operation Warning

An operation warning label is present on the console of all Polaris snowmobiles:

WARNING

• To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a Polaris dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can result in insufficient time for you to react to terrain changes, to avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehicle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located on the top of the throttle control assembly, to stop the engine. Then pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate clothing while operating this vehicle.

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

• When operating with a passenger (on approved models only), reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner’s Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss of braking ability.

• Parking brake may relax when used for long periods. Do not leave brake engaged for more than five minutes.

• Before starting the engine, check throttle, brake, and steering for proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.

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

FEATURES AND CONTROLS

General Representation

1. Fuel Filler Cap (may include a fuel gauge)

2. Ignition Switch

3. Brake Lever

4. Speedometer (may include indicator/warning lights)

5. Reverse Indicator

6. Mountain Bar

7. Engine Stop Switch (see page 54)

8. Throttle Control

9. Choke

10. Recoil Starter Handle

FEATURES AND CONTROLS

ONOFF

Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement.

1. Headlight Dimmer Switch

2. Parking Brake Lock

3. Handlebar Grip Warmer Switch

4. Thumbwarmer Switch

5. Electronic Reverse Button

Fuel Valve

The fuel valve is located under the hood. Turn the fuel valve off whenever the snowmobile is stored or parked.

1. Turn the valve clockwise to turn off the fuel supply.

2. Turn the valve counter-clock-

wise to turn on the fuel supply.

FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Operator Seat

6. Passenger Hand Hold Strap

7. Cargo Rack

8. Taillights

9. Snow Flap

10. Track

11. Suspension

12. Trailing Arm

13. Nosepan

14. Front Bumper (do not use for pulling or dragging the snowmobile)

15. Skis

FEATURES AND CONTROLS

Operator/Passenger

Raise/Lower

Backrest

The backrest is adjustable for either operator or passenger use.

1. Loosen the upper adjustment knobs to raise or lower the backrest.

2. Loosen the lower

adjustment knobs to move the backrest forward for operator use or rearward for passenger use.

3. Always tighten the

knobs.

Cargo Rack

Always secure cargo before operating. Do not exceed the rack weight limit specified on the cargo rack label. Do not allow a passenger to sit on the seat back or the cargo rack.

THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and regrease all suspension parts before making any fine-tuning adjustments.

Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The snowmobile should be methodically tested under the same conditions after each adjustment (trail and snow conditions, vehicle speed, riding position, etc.) until the best ride is achieved. Adjustments should be made to one area at a time in order to properly evaluate the change.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

THE PERFECT FIT

Front Suspension Adjustments

Always verify ski alignment before making adjustments to the IFS. See page 92 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

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

Shock Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Spring Preload Adjuster Nut

THE PERFECT FIT

Front Shock Washers

Front Suspension Adjustments

Shock Spring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease skito-ground pressure.

Front Springs

For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. Special tools are required to adjust front springs. If you feel that your front suspension needs adjustment see your Polaris dealer for more information.

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.

See your Polaris dealer for initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see your dealer.

Suspension Performance Tips

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

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

• In deep snow, a new rail slide will offer improved performance over a

worn rail slide. It can also improve top speed.

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

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

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

dealer for assistance.

Tip: Keep the suspension pivot points lubricated. This will reduce moisture and

rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. See page 65.

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 88.

THE PERFECT FIT

Eye Bolt

WideTrak Rear Suspension Adjustments

Rear Spring Settings

Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings:

1. Lift the rear of the snowmobile to relieve the rear springs.

2. Slowly lower the snowmobile and measure the distance between the ground and the running board.

3. Without letting the suspension settle, the rider should carefully mount the snowmobile.

4. Measure the distance between the ground and the same spot on the running board.

The difference between the two measurements should be approximately 1 1/2" (3.8 cm). If the difference is greater than 1 1/2", the rear spring should be adjusted equally on both sides until the desired 1 1/2" drop is obtained.

Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the rear spring eye bolt length. Adjust spring tension so there is equal tension on the long leg of each spring.

Tip: Rear spring settings will affect ski-to-ground pressure. If ski pressure is too

light it may be desirable to tighten the rear springs for an increase in ski-toground pressure.

THE PERFECT FIT

Bar

Nuts

Bolts

Nuts

Handlebar Adjustments

Standard Handlebar

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

1. Remove the mountain bar by removing nuts.

2. Using a 7/16-inch wrench,

loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear nuts). If necessary, pry the blocks apart with a screwdriver.

3. Adjust the handlebar to the

desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the snowmobile when the handlebar is turned fully to the left or right.

4. Torque the front bolts first, then torque the rear bolts. Torque the

bolts to 11-13 ft. lbs. (15-18 Nm).

5. Reinstall the mountain bar.

THE PERFECT FIT

Traction Products

n Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain.

Inspect skags frequently. Worn skags may reduce steering and braking control on hard-packed snow and ice. Replace worn skags to maintain proper balance and vehicle control.

WARNING! Loss of control can result in serious injury or death. Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard-packed snow or ice. See your dealer for assistance.

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies to, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems.

Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service.

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark ( locate the pre-ride inspection items.

Item See Page

Drive Belt Condition 81, 84

Steering System 42

Recoil Rope 43

Parking Brake Lock/Brake Lever/Brake System 40, 41, 75

Auxiliary Shut-Off Switch (Engine Stop Switch) 54

Ignition Switch 44

Taillight/Brakelight/Headlight 44

Suspension Mounting Bolts 94

Skags (Wear Bars) 93

Ski Saddle and Spindle Bolts 94

Hood Straps/Latches 43

Throttle Lever/Safety Switch 39, 54, 55

Rear Wheel Idler Bolts 89, 94

Track Alignment/Condition 42, 90

Rail Slide Condition 94

Chaincase Oil Level 67

Injection Oil Level 51

n) on the referenced pages to

PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation.

WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.

n Read and Understand Your Owner’s Manual

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

n Throttle Lever

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

Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. See page 55.

n Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated. See page 54.

PRE-RIDE INSPECTIONS

1/2 inch (1.3 cm)

Before Starting the Engine

n Hydraulic Brakes

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

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. See pages 76-77 or see your dealer for service.

Lever Feel

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

Check for the presence of air in the fluid system. See pages 76-77 or see your dealer for service.

WARNING! Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes serviced at the first sign of sponginess.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.

NOTICE: If the brake lever is squeezed tightly enough, the lock will move freely

The brake light will illuminate if the parking brake lever lock is set while the engine is running. It will also illuminate when the service brake is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.

WARNING! If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

n Track

WARNING! Operating the snowmobile with a damaged track increases the

possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle.

WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure. Driving at high speeds for extended periods of time with marginal lubrication could severely damage track rods, break track edges, and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions.

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hood Latches

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

n Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the seat latches are securely in place before every use of the snowmobile.

n Recoil Rope

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

n Transmission

Make sure the transmission is not in reverse before starting the engine (if equipped with reverse).

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.

n Lighting

Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

n Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

n Operating Area

Before driving, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.

n Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

OPERATION

CHOKE POSITIONS

OFF

HALF ON

FULL ON

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result in serious

1. Turn the fuel valve on. See

2. Turn the key to the ON

3. Pull the engine stop switch

4. If starting a cold engine,

5. If equipped with electric start, turn the key to START to crank the

NOTICE: Don’t pull the starter rope to the fully extended position and don’t allow

6. If not equipped with electric start, grasp starter handle and pull

7. Repeat the cranking procedure as needed until the engine starts.

8. After the engine starts, flip the choke toggle to the OFF position. If

engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running.

page 27.

position.

up to the RUN position.

flip the choke toggle to FULL CHOKE. Do not use the choke if starting a warm engine. Do not depress the throttle until the engine starts.

engine. Release the key to the ON position when the engine starts.

it to snap back into the housing. Damage may result. To avoid engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

slowly until the recoil engages, then pull abruptly to crank the engine.

the engine slows or wants to stop, use intermittent choking to the HALF CHOKE position.

OPERATION

Engine Break-In

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

NOTICE: Excessive heat build-up during the first three hours of operation will

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

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

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

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 50.

NOTICE: Serious engine damage can occur without the proper lubrication.

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of Premium 2-Cycle Oil for this engine. See page 103 for the part numbers of Polaris products.

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

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately.

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

OPERATION

WARNING

Track Warm-Up

A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable.

Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.

Follow these steps to ensure proper warm-up of the engine, drive train and track.

1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be approximately 4 inches (10 cm) off the ground.

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

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

revolutions.

Tip: It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

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

the snowmobile to the ground.

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

This will loosen frozen snow from the ski bottoms, allowing the snowmobile to move forward more easily.

6. The engine, drive system and track are now properly warmed up

and the snowmobile may be driven following normal safety practices.

OPERATION

WARNING

Fuel

Fuel Safety

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

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

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

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

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

• Turn the fuel valve off whenever the snowmobile is stored or parked.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Fuel

Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85).

NOTICE: Using fuels with a lower than recommended octane or operating with

Fuel Reserve Capacity (Mechanical Gauge)

There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES.

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer or Polaris Carbon Clean Plus. Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. See page 103 for the part numbers of Polaris products.

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

NOTICE: Prolonged exposure to petroleum based products may damage paint.

obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your snowmobile.

Always protect painted surfaces when handling fuel.

OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will indicate when to add oil. See page 47 for oil recommendations.

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

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

Always maintain the oil level above the tank’s low level line. This is especially important when the snowmobile 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.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. We recommend the use of Polaris 2-cycle oils for your snowmobile. Never mix brands.

Operating the snowmobile without proper engine lubrication can result in serious engine damage. Always check the oil level when refueling.

OPERATION

n Oil

Low Oil Level

Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 47 for oil recommendations.

The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

Carburetion

Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.

A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system. Either condition may be caused by improper carburetor adjustment.

CAUTION! Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments.

OPERATION

Carburetion

Jetting Guidelines

Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.

RMK carburetors are preset to operate at altitudes of 6000-8000 feet (1800-2400 m) above sea level (see page 72 for more information). Carburetors must be re-calibrated if the snowmobile is operated outside this production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures.

NOTICE: A main jet that’s too small will cause a lean operating condition and

It’s the owner’s responsibility to ensure that the correct jets are installed in the snowmobile for a geographical area. Be very careful when jetting down in warm weather. As the weather turns colder it will be necessary to re-jet upward to prevent engine damage. When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered.

may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts. Refer to your Owner’s Manual Supplement.

OPERATION

Stop Switch

n Engine Stop Switch

Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position.

n Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position. Test the throttle safety switch system daily before operation.

WARNING! Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident. If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

Test the throttle safety switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it to idle.

3. Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch must shut down the engine.

OPERATION

n Throttle Lever

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor(s) to determine what caused the safety switch to activate.

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

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

5. If the engine doesn’t start, take the snowmobile to an authorized Polaris dealer for service.

Tip: Excessive free play in the throttle cable may cause the safety switch to acti-

vate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness. When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized Polaris dealer for service as soon as possible.

OPERATION

n Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 54 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

THROTTLE

CONDITION

Emergency Starting

Your snowmobile is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. If the recoil starter system fails, an emergency start strap is provided in the kit.

OPERATION

Reverse Operation

WARNING! Improper reverse operation, even at low speeds, may cause loss of

control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.

• Shift to or from reverse only when the snowmobile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Mechanical Reverse

Make sure the shift lever is shifted completely into forward or reverse position. Some models are equipped with a reverse indicator light that will help you make that determination.

Do not force the shift lever into reverse if resistance is felt. The gears may not always be aligned for shifting into reverse, and forcing the lever may cause damage. If resistance is felt, gently apply the throttle to move the gears to a different position and try to shift again.

The transmission may not always be in the gear indicated by the shift lever. Apply the throttle slowly until you're sure which gear is engaged.

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

OPERATION

Towing

Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.

For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the snowmobile's track and a person riding in the towed object. Braking distances increase when towing loads. Slow down to maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have a rider on the towed snowmobile to operate the brake and steering when necessary.

NOTICE: Towing a disabled snowmobile with the drive belt in place can result in

serious damage to the engine and drive system. Always remove the drive belt from a disabled snowmobile before towing.

MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hangtag. These items are required by U.S. Environmental Protection Agency regulations. The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover. The ECI label should not be removed, even after you purchase the snowmobile. You may remove the factory-installed emissions information hangtag, which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 118.

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

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

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

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

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Clutch Offset Alignment

(without belt)

Drive Belt Condition 81 I I I I

Clutches (disassemble) 80 C C C

Belt Tension -- I I I I

Clutch Sheaves 84 I I I I

Engine Mounts -- I I I I

Recoil Rope 43 I I I I

Engine Mounting Plate -- I I I

Engine Torque Stop 84 I I I I

Cylinder Head Bolts -- I I I

Cylinder Base Nuts -- I I I I

Ignition Timing BTDC -- I I I

Spark Plug Condition 68 I I I I I

Exhaust Pipe 74 I I

Exhaust Retaining Springs

Hose Routing -- I I I I

Hose Condition -- I I I I

Fluid Leaks -- I I I I

Brake Pads 75 I I I I

Brake Disc -- I I I I

Parking Brakes 41 I I I I

Brake System 40,75 I

Brake fluid 76 R

Page

150 mi.

(240 km)

80 I I I

74 I I I I

(800 km)

CLUTCH

ENGINE

BRAKES

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Pilot Air Screws -- I I I

Carburetor (synchronize) 52 I I I

Idle RPM -- I I I

Throttle Lever 39,55 I I I I I

Oil Pump Lever

(synchronize)

Throttle Cable 66 L L L

Choke Cable 66 I L L L

Vent Lines -- I I I I

Throttle Position Sensor -- I I I

Choke 66 I I I

Fuel Filter 73 R R

Fuel Lines 73 I I I I I

Oil Filter 73 R R

Oil Lines 73 I I I

Oil Change N/A R R I

Air Box -- I I I I I

Drain and Water Traps 71 I I I

Auxiliary Shut-Off Switch 44 I I I I I

Throttle Safety Switch 39,54 I I I I I

Ignition Switch 44 I I I I I

Taillight 44 I I I I I

Brakelight 44 I I I I I

Headlight 44 I I I I I

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- I I I

ELECTRICAL

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- I I I

Suspension Mounting Bolts

Steering Fasteners -- I I I I C

Rear Suspension

Fasteners

Suspension Shock Oil -- I I I I

Cooling Fins and Shroud -- I I I I

Drive Shaft Bearings 66 L L L I

Jackshaft Bearings 66 L L L I

Skags (Wear Bars) 93 I I I I I

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

Ski Pivots 64 L L L L I

Ski Spindle 64 L L L L I

Steering Arm(s) 64 L L L L I

Upper/ Lower Steering Post Support Bracket

Hood Straps 43 I I I I I

Battery Fluid Level 95 I I I I I

Rear Wheel Idler Bolts and Nuts

Rear Suspension Pivot Shafts

Camber Alignment -- I I I

Radius Rod Bushings -- I

Handlebar Centering -- I

Track Alignment 90 I I I I I

Track Tension 88 I I I I I

Front Limiter Strap -- I I I I I

Rail Slide Condition 94 I

Chaincase Oil N/A I I I R I

Gearcase Oil 67 I I I R I

Page

150 mi.

(240 km)

-- I I I I I

64 L L L L I

89 I I I I I

65 L L L

(800 km)

CHASSIS

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Season

Pre-

MAINTENANCE

Lubrication

Suspension and Steering

Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 103 for the part numbers of Polaris products.

The illustration shows the lubrication points of suspension and steering components. A + indicates a grease point or fitting.

• Grease the left and right spindles. Raise the front end of the snowmobile to permit better grease entry into the spindle area.

• Lubricate both of the front ski pivots at the fittings as shown.

• Grease the jackshaft and driveshaft clutch side bearings.

• Use an aerosol lubricant on the steering post support bracket.

• Grease the steering post lower pivot.

• Grease the rear suspension pivot shafts (raise the rear of unit).

Lubrication

Rear Suspension WideTrak Rear Suspension

MAINTENANCE

Lubrication

Jackshaft Bearing

The jackshaft bearing on your model may be equipped with a grease fitting, but this component is greased for life at the factory. Additional lubrication is not required.

Driveshaft Bearing

Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal (approximately two pumps).

Throttle Cable

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

Choke and Cable

Lubricate the choke slide and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.

Coupler Greasing

Grease the couplers on the driveshaft and jackshaft.

Lubrication

n Gearcase Oil Level

Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 63. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

To check the oil level, place the snowmobile on a level surface. The oil level should be between the “safe” marks on the dipstick (1). See your Polaris dealer for the recommended oil for your snowmobile. Do not over- fill.

Clean the magnetic plug (2) every 500 miles (800 km) and whenever checking or changing lubricant.

NOTICE: Mixing brands or using non-

recommended lubricants could result in excessive wear to chain, sprockets and bearings. Always use Polaris-recommended products for your vehicle.

MAINTENANCE

Spark Plugs

It’s very important to use the correct spark plug for your snowmobile. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.

In selecting a spark plug heat range for production, a manufacturer assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner. This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure.

NOTICE: A spark plug with a heat range too high will always cause engine

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

• Use recommended spark plugs with the proper gap. Refer to your

• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).

• Always carry spare spark plugs in case of an emergency.

NOTICE: Using non-recommended spark plugs can result in serious engine

damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. Refer to your Owner’s Manual Supplement.

Owner’s Manual Supplement.

damage. Always use Polaris-recommended spark plugs.

MAINTENANCE

Spark Plugs

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

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

Tip: Incorrect fuel mixture can often cause a spark plug to appear too dark or too

light in color. Before changing spark plug heat ranges, be sure the correct main jet is installed in the carburetor(s). Refer to your Owner’s Manual Supplement.

Normal Plug

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

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

Wet Fouled Plug

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

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to 18-22

ft. lbs. (24.4-29.8 Nm).

4. Reinstall the spark plug cap.

MAINTENANCE

Intake

Foam Filter and Screen

Foam Filter

Air Intake Box

Intake Filter

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

NOTICE: Operating the snowmobile with the intake filters removed may cause

These illustrations are general representations.Your model may differ.

carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile.

MAINTENANCE

Clamp

Drain Plug

Carburetor

Water/Sediment Trap Service

Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.

WARNING! When draining the traps, fuel spillage will occur. Always work in a well ventilated area away from anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline warnings found on page 49.

Plug Cleaning Procedure

1. Turn the fuel valve off.

2. Position a container or shop towels to

catch the contaminated gasoline.

3. Slide the clamp away from the drain

plug and remove the drain plug from the sediment tube.

4. Wipe residue from the plug and reinstall

it. Reposition and tighten the clamps. Continue until all the traps have been emptied.

MAINTENANCE

Carburetor

The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed.

NOTICE: Operating the snowmobile with incorrect jetting can result in serious

Carburetor Adjustments

The frequency at which the carburetors are synchronized or balanced is important. Properly adjusted carburetors can greatly improve engine performance, fuel economy, engine life, and reliability.

If you notice any of the following conditions, the carburetor may need adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly.

MAINTENANCE

Fuel Filter/Fuel Lines

The fuel filter is located inside the fuel tank. This component requires no maintenance.

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

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

Oil Filter

The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

Tip: The direction of the arrows indicates

lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.

the direction of flow through the filter.

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

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

Drive Chain Tension

Your WideTrak is equipped with an automatic chain tensioner. No maintenance or inspection should be necessary.

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 40.

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16 inch (1.5 mm). A kit is available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety. Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive. Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch/1.5 mm).

Brake Components

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material

(replace when thickness is less than 1/16 inch/1.5 mm)

MAINTENANCE

Brakes

Brake Fluid

WARNING! After opening a bottle of brake fluid, always discard any unused

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

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

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

We recommend the use of Polaris DOT 4 high temperature brake fluid. See page 103 for the part numbers of Polaris products.

NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe

Replace brake fluid at least every two years.

up spills immediately.

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

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

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

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

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

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

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

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

8. Reinstall the gasket and cover.

MAINTENANCE

2 in. (5.1 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustment

Nut

Lights

Headlight Adjustment

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

1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall.

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

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed two (2) inches (5.1 cm) below the mark placed on the wall in step 4.

Tip: Rider weight must be included on the seat.

5. Turn the adjustment nut, located inside the hood, just below the

headlamp opening. Turn the knob in or out as needed for proper aim.

MAINTENANCE

Lights

Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel.

Headlight Bulb Replacement

1. Pinch the ends of the spring (1)

together and lift until it releases from the spring retainer.

2. Lift the spring carefully around

the wire harness (2) and flip it to the outside of the housing.

3. With the wire harness attached

to the bulb (3), withdraw the bulb from the housing.

4. Grasp the bulb by its metal base

and carefully separate the bulb from the harness.

5. Hold the new bulb by its metal base and install it into the wire har-

ness.

6. Insert the bulb into the housing. Carefully flip the spring back into

the housing, placing it around the wire harness.

7. Squeeze the spring together until it's over the spring retainer and

release.

8. Verify headlight aim. See page 78.

Taillight/Brakelight Replacement

1. Remove the screws (1) securing the

taillight housing (2).

2. Remove and replace the bulb (3).

3. Reassemble all components.

MAINTENANCE

Clutch System

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

NOTICE: If you become aware of higher than normal clutch engagement or an

NOTICE: The bushings in the weights and rollers of Polaris clutches are made

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum performance. Please see your Polaris dealer if you experience a decrease in performance.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer.

unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.

of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

MAINTENANCE

Clutch System

n Drive Belt Condition

Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. See Belt Troubleshooting on page 105.

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

Tip: A worn belt will continue to function, but will not deliver maximum perfor-

mance. Always carry a spare belt in case of an emergency.

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

MAINTENANCE

Clutch System

Drive Belt Removal

1. Stop the engine after operating in

a forward motion.

NOTICE: Do not attempt to remove the

2. Turn the ignition key off. Wait for

3. Lock the parking brake (if

4. Open the hood.

5. Remove the clutch guard retaining pin and open the clutch guard.

6. Rotate the driven clutch counterclockwise 1/4 turn by hand to

7. Firmly grasp the belt midway between the clutches and pull upward

drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal.

the engine to stop completely.

equipped).

ensure forward engagement before attempting to remove the belt.

and rearward to remove. See illustration.

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back the slack.

Tip: To ensure satisfactory belt life,

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

2. Turn the driven clutch

moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves.

3. Hold the belt down between

the sheaves and roll the bottom portion over the outer clutch sheave. Work the belt to the outer edge of the sheave.

4. Close the clutch guard and

reinstall the retaining pin.

5. Close and secure the hood

and release the parking brake.

MAINTENANCE

.010-.030 in.

(.25-.75 mm)

Clutch System

n Drive Belt Deflection

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

Place a straight edge on the belt (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm).

Drive Belt Adjustment

Belt deflection should be adjusted without removing the clutch from the jackshaft.

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

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

needed.

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

sheaves and out (counterclockwise) to decrease the distance.

3. Tighten the jam nut.

Torque Stop

Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010-.030 inch (.25-.75 mm) from the engine case.

Adjust if necessary, and lock the jam nut.

MAINTENANCE

Tool Ki t

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

Chain Tension

Maintain the proper chain tension as outlined on page 74.

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your Polaris dealer.

MAINTENANCE

Track

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the

machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift

and support the rear of the snowmobile off the ground.

2. Rotate the track by hand to

check for possible damage.

3. Carefully examine the track

along the entire length of each rod (+). Bend the track to check for breakage.

4. Replace the track if any rod

damage is found.

MAINTENANCE

Track

Track Lubrication

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication.

The slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear.

Tip: If excessive rail slide wear occurs due to poor snow conditions, additional

wheel kits are available. See your dealer for more information.

Tip: Track damage or failure caused by operation on ice or under other poor

lubrication conditions will void the track warranty.

MAINTENANCE

WARNING

Track

Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running.

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber.

WARNING! Improper track tension can cause serious damage to the snowmobile, which can result in loss of vehicle control and serious injury or death. Always maintain the track tension as specified.

1. Turn the engine off.

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

3. Place the recommended weight or downward pressure on the track

at the location specified (see chart and illustration).

Weight Measurement

10 lbs. (4.54 kg) 16 inches (40 cm) ahead of

forward idler wheel shaft bolt

Location

Measurement

3/4-1 inch (2-2.5 cm)

4. Measure at the point where the weight is hanging.

5. Check for specified slack between the wear surface of the track clip

and the plastic rail slide.

MAINTENANCE

Adjusting

Screw

Locknut

Slack Measurement

Track

10 lbs. (4.54 kg)

Idler

Shaft

Bolt

16 in. (40 cm)

Track

Track Tension

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws as necessary to provide

equal adjustment on both sides of the track.

9. Repeat the measurement on the other side of the track.

Tip: Check more frequently when snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions.

Let the track come to a stop (do not apply brakes).

11. Check track alignment (see page 90) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).

MAINTENANCE

Rails

Track

n Track Alignment

Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.

1. Safely support the rear of the

snowmobile with the track off the ground.

2. Start the engine and apply a

small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a stop (do not apply brakes).

3. Inspect track alignment by looking through the track window to

make sure the rails are evenly spaced on each side. If the track runs to the left, loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten locknuts and torque idler

shaft bolts to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

MAINTENANCE

Steering System

Steering Inspection

Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the illustration.

MAINTENANCE

10 in. (25.4 cm)

Steering System

Ski Alignment

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer.

With the handlebars in a straight-ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. The measurement between the skis at point X should be 1/8-1/4 inch (3-6 mm) greater than at point Y.

Tip: If the skis are misaligned, we recommend that your dealer correct the align-

ment, since camber adjustment may also be affected.

MAINTENANCE

Steering System

n Ski Skags

See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death.

Check skags weekly to maintain positive steering characteristics. Skags must be replaced when worn to half their original diameter. Carbide skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

1. Raise and support the front of the snowmobile so the skis are

approximately 6I (15.2 cm) from the ground.

2. Remove the attaching hardware and pry the skag downward.

3. Remove the rear end of the skag.

4. Remove the front end of the skag.

5. Reverse the steps to install a skag.

MAINTENANCE

Replace when

worn to top of

groove

Minimum

Thickness

Suspension Maintenance

n Rail Slide Wear

For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or rails.

Suspension Inspections

Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip:

n Check suspension mounting bolts for tightness.

n Check rear idler wheel bolts for tightness. See page 89.

n Check rear idler adjusting bolt locknuts for tightness.

n Check front torque arm limiter strap condition.

n Check rail slide condition.

n Check track tension. See page 88.

n Lubricate/grease all suspension components. See page 64.

n Check ski runner/skag condition. See page 93.

n Check ski spindle bolts for tightness.

n Check tie rod end nuts for tightness.

MAINTENANCE

WARNING

Upper Mark

Lower Mark

Battery

Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention.

KEEP OUT OF REACH OF CHILDREN.

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Call physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, open flames, cigarettes, etc. away. Ventilate when charging or using in closed space. Always shield eyes when working near batteries.

Battery Fluid

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

NOTICE: Tap water contains minerals

that will damage a battery and shorten its life. Use only distilled water to refill your battery. Never allow cleaning solution or tap water to enter the battery.

MAINTENANCE

Battery

Battery Connections

Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

Battery Removal

WARNING! Improperly connecting or disconnecting battery cables can result in

an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

1. Disconnect the battery hold-down straps.

2. Remove the battery vent tube from battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable last.

5. Carefully lift the battery out of the snowmobile. Do not tip it side-

ways or spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the vehicle.

MAINTENANCE

Battery

Battery Installation

WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte

as severe burns may result.

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder. Attach the hold down strap.

3. Install the battery vent tube. The vent tube must be free of obstruc-

tions and securely installed. Route the vent tube properly to prevent kinks and to allow for proper drainage.

WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last to avoid the possibility of explosion.

4. Coat the terminals with dielectric grease or petroleum jelly.

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

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

7. Verify that cables and vent tube are properly routed.

Polaris Widetrack LX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual