Polaris Trail Touring Deluxe, 340 Touring 2007, Trail Touring DLX 2007, WideTrak 2007 Owner's Manual

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9920449 Rev 02 Printed in USA

WARNING

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

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

WARNING

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

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at Polaris we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.

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

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

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

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

Copyright 2006 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. 2007 340 Touring/Trail Touring DLX/WideTrak Owner's Manual P/N 9920449

TABLE OF CONTENTS

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

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

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

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 48

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 128

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 145

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

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

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

Key Number: ___________________________________________________________

Important Notes for Owners and Drivers

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

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

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

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

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

Air Pollution

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

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

SAFETY

Operator Safety

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

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

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 76 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

WARNING

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

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

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

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

SAFETY

Operator Safety

Stay Clear of Track

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

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 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.

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

Riding Position

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

NOTE: Use of a backrest may hinder your weight shifting ability. This

could affect your ability to control this rider-active vehicle in certain extreme driving situations.

Riding Apparel

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 21.

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.

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.

WARNING

Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury.

051039

0006.31

SAFETY

Operator Safety

Survival Preparation

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

For added protection, carry the following items on your snowmobile at all times:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

• Tow Rope • Owner's Manual

• Extra Oil • First Aid Kit

• Fuel Deicer

SAFETY

Operator Safety

Disabled Operators

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

Cargo Overload

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

Rider Capacity

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

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

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

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

WARNING

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

SAFETY

Excessive Speed

Always observe all laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH, your machine will travel about 180 feet in two seconds.

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

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.

SAFETY

Operator Safety

Driver Awareness

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

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

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Avoid travelling on frozen bodies of water.

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.

SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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

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

For more information about avalanche training and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org.

SAFETY

Operator Safety

Ice and Snow Build-up

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

Driving on Slippery Surfaces

WARNING

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

WARNING

Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Never attempt an abrupt change of direction when operating on slippery surfaces. Slow down and use extra caution when operating on slippery surfaces.

SAFETY

Operator Safety

Driving Downhill

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

WARNING

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

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

SAFETY

Operator Safety

Driving in Hilly Terrain

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

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

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

Drive Belt

Do not operate the engine with the drive belt removed.

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

Intake Silencer

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

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

WARNING

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

SAFETY

Operator Safety

Clutch Guard

Do not operate the engine with the clutch guard removed.

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

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

Maneuverability

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

Maintenance

SAFETY

Operator Safety

Inadequate Snow Conditions

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

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

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

WARNING

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

CAUTION

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

SAFETY

Operator Safety

Driving Responsibly

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

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

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

• Don't "jump" your snowmobile. Jumping may injure your back because of spinal compression. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

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

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

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

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (_F)

WINDCHILL CHART (_C)

Wind

Speed

MPH

Actual Thermometer Reading (_F)

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

Equivalent Temperature (_F)

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

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

5 3631251913 7 1 -5-11-16

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

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

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

15 32 25 19 13 6 0 -7 -13

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

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

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

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

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

30 28 22 15 8 1 -5 -12

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

35 28 21 14 7 0 -7 -14

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

40 27 20 13 6 -1 -8 -15

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

45 26 19 12 5 -2 -9 -16

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

50 26 19 12 4 -3 -10 -17

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

55 25 18 11 4 -3 -11

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

60 25 17 10 3 -4 -11

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

Frostbite in >>

30 min. 10 min. 5 min.

Wind

Speed

KPH

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Frostbite in >>

30 min. 10 min. 5 min.

SAFETY

Safety Decals and Locations

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

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

Clutch Cover Warning

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

WARNING

Do not operate engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself -- see your dealer.

Airbox Warning

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

CAUTION

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

Pressure Cap Warning

This warning decal is found on the coolant bottle cap of liquid cooled models:

WARNING

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

SAFETY

Safety Decals and Locations

Track Warning

The track warning decal is on the rear of the tunnel:

WARNING

Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death.

Passenger Warning

Polaris touring models and the WideTrak are designed for the operator and one passenger. For more information on operating with a passenger, see page 11.

The passenger warning decal is located at the right side of the steering post:

WARNING

This vehicle is designed for operator and ONE passenger only.

SAFETY

Safety Decals and Locations

Standard Reverse Warning

The Polaris WideTrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument housing:

WARNING

Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.

For more information, see Owner's Manual.

SAFETY

Safety Decals and Locations

Electronic Reverse Warning

Polaris snowmobiles equipped with electronic reverse have a reverse warning decal on the lower dash:

WARNING

Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.

For more information, see Owner's Manual.

If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

• Elevation setting (above 6000 feet): push and hold for longer than 5 seconds to set. Let go of button at desired setting-fast flash for high elevation, slower flash for low. Setting will remain until changed.

SAFETY

Safety Decals and Locations

Operation Warning

The operation warning decal is located on the console:

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 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

Some Polaris snowmobiles are equipped with special features. Operating controls and special feature controls are illustrated on this page. Not all models come with all special features. See your Owner's Manual Supplement.

1. Fuel Filler Cap

2. Ignition Switch

3. Accessory Plug

4. Brake Lever

5. Electronic Fuel Gauge

6. Speedometer

7. Tachometer

8. Electric Shock Control Gauge

9. Engine Stop Switch

10. Throttle Control

11. Hood Hold-Down Straps

12. Recoil Starter Handle

13. Choke

14. Headlight Dimmer Switch

15. Parking Brake Lock

16. Handlebar Grip Warmer Switch

17. Thumbwarmer Switch

18. Electronic Reverse Button

19. Electronic Shock Control Button

Touring Models

WideTrak

FEATURES

HIGH

OFF

LOW

1. Hood

2. Headlight

3. Passenger Lumbar Adjuster

4. Windshield

5. Handlebar

6. Operator Seat

7. Passenger Seat

8. Taillights

9. Rear Bumper

10. Snow Flap

11. Passenger Grab Handle

12. Track

13. Suspension

14. Trailing Arm

15. Nosepan

16. Front Bumper

17. Ski

18. Grab Handle Heater Switch (Accessory)

19. Passenger Hand Hold Strap (WideTrak)

FEATURES

Passenger Seat

The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob.

On Touring models, the passenger seat and cargo bag are removable to provide open storage for transporting larger items.

1. Remove the cargo bag.

2. Push down on the seat latch lever at the lower rear of the passenger seat.

3. Lift up the seat and remove it from the chassis.

4. Reverse the procedure to reinstall the seat and cargo bag.

Cargo Rack

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

Adjustment Knob

Latch Lever

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments.

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

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. Trailing arms

IFS Adjustment Options

• Shock damping (if equipped with Indy Select shocks)

• Front shock spring preload

• Optional springs

• Toe (ski alignment) (see page 116)

• Camber (see your dealer)

THE PERFECT FIT

Front Suspension Adjustments

For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. To determine if your machine is using full travel, push the jounce bumper down on the shock rod until it contacts the body and test ride the machine. The bumper will move up on the rod in relation to the amount of travel that was used during the ride. If the travel is full, the bumper will be seated at the top of the rod.

Shock Components

The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Pre-

load Adjuster Nut

WARNING

Always verify ski alignment before making adjustments to the IFS. See page 116 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

THE PERFECT FIT

Front Suspension Adjustments

Shock Damping (Indy Select Shock)

Adjustments to the compression stiffness of Indy Select shocks can be made by turning the adjustment screw located near the base of the shock (+). This adjustment is the easiest to perform and it should be considered first.

The factory setting for this shock is the softest position, with the adjusting screw all the way out (counterclockwise). If bottoming occurs, the Indy Select feature should be used to achieve the desired ride. The shocks have a wide range of adjustment capability. By turning the screw clockwise, the compression of the shock increases, stiffening the ride. When adjusting these shocks, we recommend that you turn the screw only 1/4 turn at a time, then test ride. Always adjust both shocks equally.

THE PERFECT FIT

Front Suspension Adjustments

Spring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-toground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment.

To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch of preload beyond the factory settings, and ensure that both sides are adjusted the same. When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body.

NOTE: Not all models have shocks with thread adjustable spring pre-

load. See your dealer for more information.

Front Springs

For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.

CAUTION

Always leave one thread showing above the adjuster nut. On models equipped with a plastic adjuster nut, if the nut is unscrewed from the threaded body, the nut will break.

Low

Preload

High

Preload

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.

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

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.

THE PERFECT FIT

Rear Suspension Adjustments

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 setup. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride.

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

worn rail slide. It can also improve top speed.

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

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

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

dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce

moisture and rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. See page 80.

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 112.

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.

Take the first measurement with no rider and with the rear suspension at full extension.

NOTE: The rear bumper may need

to be lifted upward slightly to fully extend the rear suspension.

Next, have the rider drop down hard on the seat and bounce up and down several times, collapsing the rear suspension. With the rider seated, measure the distance between the ground and the rear bumper at the exact location used for measurement X. This is measurement Y.

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration for reference. The ideal amount of Sag for the EDGE rear suspension is four inches (X-Y=4).

If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment, optional torsion springs (softer or stiffer, respectively) may be required. This is only an initial set-up, and final spring preload may vary based on rider preference and riding conditions.

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Rear Spring Tension

To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.

The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.

Low Tension Medium Tension High Tension

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Indy Select Rear Shock

Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. Locate the adjustment screw near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride. There are approximately three full turns of adjustment available.

If bottoming continues after the screw has been turned fully clockwise, the torsion spring should be adjusted (see page 37). Return the screw to its original starting position after the torsion spring has been tightened.

Adjustment Screw

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Optional Coil Springs

Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information.

Suspension Coupling

On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other. There are two types of rear suspension coupling.

Front To Rear Coupling and the Front Rear Scissor Stop (FRSS)

The front rear scissor stop (FRSS) couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm.

When hitting a bump, the front torque arm starts to compress. The FRSS links that movement to the rear torque arm, causing it to compress and raise the rear suspension up as one, allowing the suspension to hit the bump only once and reducing kickback.

The factory setting is usually adequate for all riders and conditions.

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Suspension Coupling

Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS)

The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.

Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS. This dot is on the longest end of the scissor stop.

Moving the RRSS to a higher position will have the following effects on the suspension:

• Reduced weight transfer.

• Improved chatter bump ride.

• Improved cornering performance.

THE PERFECT FIT

EDGE 136 Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions.

To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.

To increase weight transfer or ski lift during acceleration, move the RRSS to the rearward hole on high position. The RRSS may also be rotated to a lower position for even more weight transfer if desired.

Stock Position - This setting is most desirable for trail riding.

Medium or High Position (standard hole location) - This setting will decrease weight transfer.

Rearward Upper Position (optional hole location - This setting will increase weight transfer.

NOTE: Your dealer can help you with initial setup and additional setup

instructions to help you achieve your optimum ride. A scissor stop tool is also available from your dealer.

Medium/High

Stock

Rearward Upper

THE PERFECT FIT

WideTrak Rear Suspension Adjustments

Rear Spring Settings

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

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

2. Slowly lower the machine and measure the distance between the

ground and the running board.

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

mount the snowmobile.

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

running board.

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

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

NOTE: 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-to-ground pressure.

Eye Bolt

THE PERFECT FIT

Handlebar Adjustment

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

1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2).

2. Using a 7/16I (11 mm) wrench,

loosen the four nuts (3) on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).

NOTE: If necessary, pry the blocks

apart with a screwdriver.

3. Adjust the handlebar to the

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

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

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

5. Reinstall the handlebar cover.

THE PERFECT FIT

Traction Products

Studs

Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.

NOTE: Polaris does not recommend the use of traction products on

WideTrak snowmobiles.

Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

See your dealer about installing studs and/or carbides.

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.

When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. See your dealer.

CAUTION

Always install wear strips before installing studs. Failure to install wear strips may result in cooler or tunnel damage. See page 46.

Never add shims to the wear strip. Track damage will result because of lack of clearance between upper carrier wheels and track.

Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel.

CAUTION

Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. The center of

the stud must be at least 1 1/8

I (2.86 cm) from the outside edge of the track.

THE PERFECT FIT

Traction Products

nCarbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 117.

If your machine has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.

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

WARNING

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

THE PERFECT FIT

Traction Products

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. See your dealer for more information.

Some models are manufactured with tunnel wear strips or wear strip coolers installed. Wear strips are designed for a specific stud length. See

your dealer's studding chart for recommended traction accessories.

Components (viewed from rear of track)

1. Top of tunnel

2. Wear strip

3. Track

4. Wear strip mounting holes

CAUTION

Whenever wear strips are relocated, be sure there's adequate stud clearance to the heat exchangers. Lack of clearance may result in damage to heat exchangers.

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

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

NOTE: Exhaust systems are critical safety areas that must use

approved Polaris parts. Please see your Polaris dealer for service.

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

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

Item See Page

Drive Belt Condition 105, 108

Steering System 53

Recoil Rope 54

Coolant Level 93

Parking Brake Lock/Brake Lever/Brake System 50, 52, 97

Auxiliary Shut-Off Switch (Engine Stop Switch) 55

Ignition Switch 55

Taillight/Brakelight/Headlight 55

Suspension Mounting Bolts 119

Skags (Wear Bars) 117

Ski Saddle and Spindle Bolts 119

Hood Straps/Latches 54

Seat Latches (if equipped) 54

Throttle Lever/Safety Switch 66, 67

Rear Wheel Idler Bolts 113

Tether Switch/Strap 55

Track Alignment/Condition 53, 114

Rail Slide Condition 118

Chaincase Oil Level 84

Injection Oil Level 63

PRE-RIDE INSPECTIONS

Before Starting the Engine

Read and Understand Your Owner's Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated. See page 66.

WARNING

Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hydraulic Brakes

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

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 99 or see your dealer for service.

NOTE: If the brake lever feels “spongy” when squeezed, check the

brake fluid level and condition. Add fluid as needed. See page

98.

WARNING

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

1/2I (1.3 cm)

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Mechanical Brakes

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

Brake Lever Travel

Firmly depress the brake lever. Measure the distance (+) between the lever and brake block. The distance should be no more than 3/4I (1.9 cm).

If the distance is greater than this recommendation, the brake cable must be adjusted.

3/4I (1.9 cm)

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

If your model is equipped with the parking brake lever lock, use the lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock (if equipped)

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.

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

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

The brake light on the console will light up if the parking brake lever lock is set while the engine is running. It will also be lit 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 and release it. The lock will return to the unlock 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.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

n Track

NOTE: Track damage or failure caused by operation on ice or poor

lubrication conditions voids the track warranty.

WARNING

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

WARNING

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

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

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 Ignition Switch

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

n Tet her Sw i tch

If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

n Lighting

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

n Mirror Adjustment (if equipped)

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

n Operating Area

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

OPERATION

Starting the Engine

1. Turn the fuel valve on. See page

60.

2. Turn the key to the ON position.

3. Pull the engine stop switch up to the RUN position.

4. If starting a cold engine, flip the choke toggle to FULL ON. Do not use the choke if starting a warm engine.

NOTE: Do not depress the throttle

until the engine starts.

5. If equipped with electric start, turn the key to START to crank the engine. Release the key to the ON position when the engine starts.

6. If not equipped with electric start, grasp the recoil rope handle and pull slowly until the recoil engages; then pull abruptly to crank the engine.

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

8. After the engine starts, flip the choke toggle to the OFF position. If the engine slows or wants to stop, use intermittent choking to the HALF ON position.

WARNING

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 49.

WARNING

Don't pull the starter rope to the fully extended position and don't allow it to snap back into the housing. Damage may result.

To avoid injury and/or engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

CHOKE TOGGLE

POSITIONS

OFF

HALF ON

FULL ON

OPERATION

Engine Break-In

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

CAUTION

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

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

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

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 63.

Oil Recommendations

Engine lubrication comes from oil added to the fuel and oil injection systems. On Polaris snowmobiles equipped with a variable exhaust system (VES), Polaris highly recommends the use of only VES II 2 Cycle Oil. See the table below for additional oil recommendations. See page 128 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

CAUTION

Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately.

Engine

Style

Premium

2-Cycle

Premium Gold

2-Cycle

VES II

2-Cycle

Fan Cooled Good Better N/A

Liquid Cooled Good Better N/A

Liquid Cooled w/VES Good Better Best

CAUTION

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

OPERATION

Track Warm-Up

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

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

2. Start the engine and allow it to warm

up two to three minutes.

3. Depress the throttle abruptly and

allow the track to rotate several revolutions.

NOTE: It will take longer to warm up the

track sufficiently during colder outdoor temperatures.

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

the machine to the ground.

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

to loosen snow and ice.

WARNING

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

WARNING

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

OPERATION

Fuel Valve

Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on.

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

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

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

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

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

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

WARNING

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

OFF

OPERATION

Fuel

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

NOTE: Some engines require premium fuel. See your Owner’s Manual

Supplement.

CAUTION

Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine.

OPERATION

Fuel

Fuel Reserve Capacity (Mechanical Gauge)

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

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 128 for the part numbers of Polaris products.

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

CAUTION

Prolonged exposure to petroleum based products may damage paint. Always protect painted surfaces when handling fuel.

OPERATION

Oil

n Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile.

n Low Oil Level

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

Always check the oil level when refueling. Maintain the oil level above the tank's low level line. When the oil reaches the low level mark, add one U.S. quart of recommended oil. See page 58 for oil recommendations.

NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil

flow. See your Polaris dealer for recommended replacement parts.

CAUTION

Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refueling. Add oil as needed.

OPERATION

Carburetion

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

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

WARNING

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

OPERATION

Carburetion

Jetting Guidelines

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

The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and ambient temperatures between -15_ to +5_ F. (-26_ to -15_ C). Carburetors must be re-calibrated if the snowmobile is operated outside this production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures. See page 89 for more information.

NOTE: It's the owner's responsibility to ensure that the correct jets are

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

CAUTION

A main jet that's too small will cause a lean operating condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner's Manual Supplement.

OPERATION

n Engine Stop Switch

Push down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting.

n Throttle Safety Switch

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

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.

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.

OPERATION

Throttle Lever

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

1. Turn the ignition switch to OFF.

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

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

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

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

Excessive freeplay in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service.

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

WARNING

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

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

OPERATION

Emergency Starting

Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. On non-electric-start models, if the recoil starter system fails, an emergency start strap is provided in the kit.

1. Open the hood.

2. Open the clutch guard.

3. Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension.

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

5. Pull the strap abruptly so the strap comes free of the clutch while starting the engine. Repeat until the engine starts.

6. Close the clutch guard.

7. Close and secure the hood.

WARNING

Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure. DO NOT wrap the start strap around your hand. Keep all bystanders and loose clothing away from the snowmobile when using the emergency starting procedure.

OPERATION

Reverse Operation

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.

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.

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described on page 72. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your vehicle is clear.

3. Push the yellow reverse button (+)

on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the machine is in reverse.

4. Apply the throttle slowly to make sure the machine is in reverse.

NOTE: The maximum engine RPM will be 6000 when in reverse.

NOTE: If the engine stops running, the snowmobile will be in forward

gear when it's restarted.

OPERATION

Reverse Operation

Electronic Reverse (PERCt)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

3. Apply the throttle slowly to make sure the machine is in forward.

Altitude Setting

At higher altitudes (above 6000 feet), the engine will require a different ignition setting to improve the success of the reverse system. To set for a higher altitude, start the engine and hold the button down until the light on the instrument panel flashes rapidly, then release the button.

To set the reverse for lower elevations, continue holding the button down until the reverse indicator light blinks slowly. Once set, it's stored in memory until changed, whether the machine is running or not.

OPERATION

Daily Storage

At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground.

Remove the key and cover the machine.

To w i n g

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

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

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.

CAUTION

Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system. Always remove the drive belt from a disabled snowmobile before towing.

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. The emission control system designation per SAE J1930 is EM. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty on page 143, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed, including the emission-related maintenance outlined in these sections of the manual.

You must inspect the air intake system on your snowmobile prior to each use (including the airbox foam filter and hood foam filters) and clean these components as necessary. Polaris considers the specified maintenance for the spark plugs, oil changes, air intake system and exhaust valves to be critical emission-related maintenance. The specified maintenance for the fuel filter is recommended additional emissionrelated maintenance. Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

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 145.

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

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

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

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

CAUTION

Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

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.

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset (without belt)

104 II I

Drive Belt Condition 105 II II

Clutches (disassemble) 103 CCC

Belt Tension -- II II

Clutch Sheaves 103 II II

ENGINE/COOLING

Engine Mounts -- IIII

Recoil Rope -- IIII

Engine Mounting Plate -- II I

Engine Torque Stop 109 IIII

Cylinder Head Bolts -- II I

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- II I

VES System -- CCC I

Coolant Level 93 IIRI

Water Pump Drive Belt 105 II I

Coolant Hose -- IIII

Heat Exchangers -- II I I I

Coolant Circulation -- II I

Coolant Leaks -- IIII

Spark Plug Condition 85 II IRI

Exhaust Pipe 91 II

Exhaust Retaining Springs

91 IIII

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing -- II II

Hose Condition -- IIII

Fluid Leaks -- IIII

Brake Pads 97 II II

Brake Disc -- IIII

Parking Brakes 52 II II

Brake System 50, 97 I

Brake Fluid 98 R

FUEL MANAGEMENT

Pilot Air Screws -- III

Carburetor (synchronize)

89 II I

Idle RPM -- II I

Throttle Lever 67 II I I I

Oil Pump Lever (synchronize)

-- III

Throttle Cable 82 LLL

Choke Cable 82 LL L

Choke 82 II I

Vent Lines -- IIII

Throttle Position Sensor

-- III

Fuel Lines 88 II I I I

Fuel Filter 88 RR

Oil Filter 88 RR

Oil Lines -- III

Oil Change -- RR

Air Box -- II I I I

Drain and Water Traps 90 II I

ELECTRICAL

Auxiliary Shut-Off Switch

55 II I I I

Throttle Safety Switch 66 II I I I

Ignition Switch -- II I I I

Taillight 55 II I I I

Brakelight 55 III I I

Headlight 55 II I I I

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Ski Toe Alignment -- II I

Suspension Mounting Bolts

-- II I I I

Steering Fasteners -- II I IC

Rear Suspension Fasteners

-- II I I I

Suspension Shock Oil -- II II

Cooling Fins and Shroud

-- II II

Drive Shaft Bearing 81 LL L I

Jackshaft Bearings 121 LL L I

Skags (Wear Bars) 117 II I I I

Ski Saddle/Spindle Bolts

-- II I I I

Ski Pivots 80 LLL L I

Ski Spindle 80 LLL L I

Steering Arm(s) -- I

Upper / Lower Steering Post Support Bracket

80 LL L L I

Drive Chain Tension 96 II I I I

Hood Latches 54 II I I I

Battery Fluid Level 124 II I I I

Rear Wheel Idler Bolts 113 II I I I

Idler Bolt Jam Nut 113 II I I I

Rear Suspension Pivot Shafts

80 LL L

Camber Alignment -- II I

Radius Rod Bushings -- I

Handlebar Centering -- I

Tether Switch and Strap 55 III I I

Track Alignment 114 II I I I

Track Tension 112 II I I I

Front Limiter Strap -- II I I I

Rail Slide Condition 118 I

Chaincase Oil 84 II IRI

Gearcase Oil 83 II IRI

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 128 for the part numbers of Polaris products.

The illustration shows the lubrication points of suspension and steering components. Grease the left and right spindles. Raise the front end of the machine to permit better grease entry into the spindle area.

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

• Grease the jackshaft and driveshaft clutch side bearings.

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

• Grease the steering post lower pivot.

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

MAINTENANCE

Lubrication

EDGE 136 Rear Suspension

WideTrak Rear Suspension

Driveshaft Bearing

Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

MAINTENANCE

Lubrication

Jackshaft Bearing

Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Push the clutch back onto the shaft and replace the clutch retaining bolt. Torque to 18 ft. lbs. (24.4 Nm).

Coupler Greasing (WideTrak)

Grease the couplers on the driveshaft and jackshaft.

Throttle Cable

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

Choke and Choke Cable

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

Jackshaft

Driveshaft

Transmission

MAINTENANCE

Lubrication

n Gearcase Oil Level (WideTrak)

Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 76. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

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

NOTE: Clean the magnetic

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

CAUTION

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

Lubrication

n Chaincase Oil

Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 76. Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil.

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 128 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on

a level surface.

2. Remove the dipstick (1) and view the oil level on the dipstick.

3. Add the recommended oil as needed. Do not overfill.

4. Clean the magnetic plug (2).

5. Reinstall the dipstick.

MAINTENANCE

Spark Plugs

A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.

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.

NOTE: Incorrect fuel mixture can often cause a spark plug to appear

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

CAUTION

Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner’s Manual Supplement.

• Use recommended spark plugs with the proper gap.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

• Always carry spare spark plugs.

WARNING

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

MAINTENANCE

Spark Plugs

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.

NOTE: The tip should not be white. A white insulator tip indicates over-

heating, caused by use of an improper spark plug or incorrect carburetor/throttle body 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.

4. Torque the spark plug to specification. See page 85.

5. Verify that gap is within specification. See your Owner’s Manual Supplement.

6. Reinstall the spark plug cap.

MAINTENANCE

Intake Filters

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

NOTE: These illustrations are general representations. Your model

may differ.

CAUTION

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

MAINTENANCE

Fuel Filter/Fuel Lines

See your Polaris dealer for replacement of the in-tank fuel filter every 1000 miles (or annually).

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

Oil Filter

The oil filter should be changed annually or every 1000 miles (1600 km). Inspect oil line condition at 1000 miles (1600 km). Polaris oil filters are specially designed for use on Polaris products. We strongly recommend the use of only Polaris replacement parts. See page 58 for oil recommendations.

EDGE models use an oil filter that's built into the oil sending unit located in the bottom of the oil tank. After changing the oil filter, bleed the oil injection system of all trapped air. See your dealer for instructions, or have your dealer perform the filter change and bleeding operation for you.

NOTE: The direction of the arrow indicates the direction of flow through

the filters.

CAUTION

Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.

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.

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

CAUTION

Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly.

MAINTENANCE

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 at least every 2000 miles (3200 km) and inspected for contamination.

1. Turn the fuel tank supply valve off.

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

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

4. Wipe residue from the plug and reinstall it. Reposition and tighten the clamps. Continue until all traps have been emptied.

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 60.

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

Variable Exhaust System (VES)

Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned.

NOTE: To ensure maximum performance and minimize required main-

tenance, follow the oil recommendation chart on page 58. The use of other lubricants may cause improper function of the valve mechanism and increase the frequency of required cleaning due to excessive build-up of carbon deposits.

WARNING

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

MAINTENANCE

Cooling System (WideTrak)

The cooling system on liquid cooled models consists of the following major components:

• Coolant bottle

• Water pump

• Cylinders

•Heads

• Inlet and outlet manifolds

• Pressure cap

• Heat exchangers

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your Polaris dealer.

When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 128 for the part numbers of Polaris products.

NOTE: Never add tap water to the cooling system. Minerals cause

deposits and may react adversely with the metals in the engine and cooling system.

MAINTENANCE

Cooling System (WideTrak)

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. See your dealer.

n Coolant Level

The engine coolant level is controlled by the recovery system. The recovery system components are:

• Coolant bottle or overflow tank

• Engine filler neck

• Pressure cap (on some models)

• Connecting hoses

The coolant level in the coolant bottle must be maintained at the recommended level shown on the coolant bottle to prevent overheating and serious engine damage. The level on some models must be maintained between the minimum and maximum marks. Other models require the coolant level to be maintained at the “full cold” line when the engine is cold.

CAUTION

Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage. Always maintain the coolant level as recommended.

MAINTENANCE

Cooling System (WideTrak)

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

MAINTENANCE

Cooling System (WideTrak)

Bleeding the Cooling System

Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part.

Recovery System

If the coolant level becomes low in the coolant bottle, bleed the system of any trapped air. Visually inspect the coolant filter (+) and replace it if it's dirty.

1. Fill the coolant bottle with coolant to the maximum mark.

2. Elevate the front end of the machine

slightly to aid bleeding of the heat exchangers.

3. Remove the pressure cap and add coolant to the top of the filler

neck.

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

5. Run the engine at various RPMs for two to three minutes to purge

the system of trapped air.

6. Close the lever lock and check the coolant bottle fluid level. Add

coolant if necessary to the maximum mark.

WARNING

Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.

MAINTENANCE

Drive Chain Tension

Check drive chain tension weekly and before each long trip. To obtain correct chain tension:

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

2. Loosen the adjuster bolt jam

nut (1).

3. Finger tighten the adjuster

bolt (2) until it can no longer be adjusted by hand, then back off 1/4 turn.

4. Tighten the jam nut while

holding the adjuster bolt. Torque to 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 50.

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

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the machine to an authorized Polaris dealer for inspection and adjustment.

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace when thickness is less than 1/16I/1.5 mm).

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

I).

Polaris Trail Touring Deluxe, 340 Touring 2007, Trail Touring DLX 2007, WideTrak 2007 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual