Polaris 550 Transport manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. Be sure to visit us online at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- at[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful info rmation for own ers and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6[...]

4 INTRODUCTION V ehicle Identification Numbers Record your snowmo bile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a Polaris key b lank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.[...]

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourag e governments to adopt rigorous safety training pro - grams that encourage protection of ou r environment, including wildlife and vegetation. Snowmobile clubs and o ther organizations are wo rking together to pro- te[...]

6 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

7 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 72 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. WAR N I N G Driving a snowmobile requires your full attenti on. DO NOT drink alcohol or use drugs or medications be[...]

8 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the en gine running . T urn off the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then restart[...]

9 SAFETY Operator Safety Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather fore- cast, especially the windchill, and dress accordingly . See the chart on page 21. Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds establ[...]

10 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 un der many co nditions, the proper position is to be seated with both feet on the ru nning boards and both hands on th e handlebar grips for pro[...]

11 SAFETY Operator Safety Disabled Operators Safe operation of this rid er-active vehi cle requires good judgement and physical skills. Operators with cognitiv e or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Cargo Overload T oo much weight on the rear of th e machine may reduce y[...]

12 SAFETY Excessive Speed Always observe all laws gove rning snowmobile op eration and speed limits. Always be alert and pay atten tion to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the ap proximate number of feet per sec- ond your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If yo u [...]

13 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling 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 d[...]

14 SAFETY Operator Safety Avalanches Snowmobilers should always be properl y trained and equipped before traveling in mountainous terrain: • T ake a n avalanch e class • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don't have to be sno[...]

15 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. Driving on Slippery Surfaces WAR N I N G Ice and snow b[...]

16 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Appl y just enough throttle to keep the clutch engaged, allow ing the engine 's compression to help slow the machine and keep it fro m rolling freely downhill. WAR N I N G When driving on long downh[...]

17 SAFETY Operator Safety Driving in Hilly T errain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you mu st cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and av oid possible roll-over . Slow down when reaching the [...]

18 SAFETY Operator Safety Clutch Guard Do not operate the engine with the clutch guard r emoved. The clutch guard is designed to protect the operator from metal parts if the clutch shoul d fail. Although th e ch ance of failure is ex tremely remote, don't defeat the purpose of the safety guard by removing it. Clutches Do not attempt to service[...]

19 SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are includ ed on some Polaris snow mobiles. 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 reco mmends closing the upper hood closure. Since snow provid[...]

20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the mos t docile condi- tions may become dangerous if oper ators drive improperly . If you 're new to snowmobiling, acquaint your self with the machine and with what it will and won't do under va rious conditions. Even seasoned driv- ers should s[...]

21 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you determine when tem- peratures become da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperature ([...]

22 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this ma nual differ from the decals on your snow mobile, always read and follow the instructions of the de[...]

23 SAFETY Safety Decals and Locations T rack W arning 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. P assenger Warning Polaris touring models are designed for the operator and one passenger . For m[...]

24 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 con- trol resulting in seriou s injury or death. T o avoid loss of co n- trol, always: • Look behind before and while[...]

25 SAFETY Safety Decals and Locations Operation W arning The operation warnin g decal is located on the console: WARNING • T o avoid serious injury or death, read and understa nd all warnings and the Owner's Manual before oper ation. If manual is missing, con- tact a Polaris dealer for a rep lacement. • This vehicle is capable of high spee[...]

26 FEA TURES Some Polaris snowmobiles are equipp ed with special features. Operat- ing controls and special feature cont rols are illustrated on this page. Not all models come with all special featur es. See your Owner's Manual Supplement. 1. F uel Filler Cap 2. Ignition Switch 3. Br ake Lever 4. Speedomet er 5. T achometer 6. Engine Stop Swit[...]

27 FEA TURES 1. F ront Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Handlebar 6. Oper ator Seat 7. P assenger Grab Hand le 8. P assenger Seat 9. P assenger Backrest 10. Suspension 11. T r ack 12. T railing Arm 13. Nosepan 14. Ski 15. T aillights 16. Rear Bumper 17. Snow Flap 3 2 6 4 5 8 11 1 10 12[...]

28 FEA TURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest forward for operator use or rearward for passenger use. 3. Always tighten the knob s securely after adjusting. Operator/Passenger Raise/[...]

29 THE PERFECT FIT F ront Suspension Adjustments Independent F ront 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 cond itions. W e recommend starting with factory settings and [...]

30 THE PERFECT FIT F ront Suspension Adjustments For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. T o determine if your machine is using full travel, push th e jou nce bumper down on the shock rod until it contacts the body and test ride the machine. The bumper will move up o[...]

31 THE PERFECT FIT F ront Suspension Adjustments Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to- ground pressure. Wh en adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o increase front shock spring preload, gra[...]

32 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension des igns and adjust ments involve a compromise, or t [...]

33 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines th e position at which the spring pre- load should be set. However , this ma y vary with riding style. W ith a little experimentation, each rider can find a preferred se tup. These adjustments are easy to make, involv e very little time or[...]

34 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustments Initial Spring Preload Setting (Sag Method) T o set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bum[...]

35 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustments Rear Spring T ension T o adjust rear torsion spring tension, rotate t he three-position cam using the engine spark plug tool. Diff erent rate torsion springs are available if a firmer ride is desired. See yo ur dealer for more information. The following information is provided only as a guide[...]

36 THE PERFECT FIT EDGE 136 Rear Susp ension 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 adjust- ment screw near the base of the shock. In half-turn incre ments, turn the screw clockwise to increase compression valving and stiff[...]

37 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustments Optional T orsion Springs Different rate torsion springs are ava ilable for some shocks if a firmer ride is desired. Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam[...]

38 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustments Suspension Coupling Rear T o 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 ar m and limits the am ount of in depen- dent movement be tween the rear torque and the front torque arm. Adjus[...]

39 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustments W eight T ransfer 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 condi- tions. T o decrease weight transfer under acceleration (for improved c[...]

40 THE PERFECT FIT Handlebar Adjustment Follow these steps to adjust handle bar angle at the handlebar blo ck. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7/16-inch wrench , loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear[...]

41 THE PERFECT FIT T raction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to th e 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. Use[...]

42 THE PERFECT FIT T raction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain prop er vehicle steering and control. See page 103. If your m[...]

43 THE PERFECT FIT T raction Products W ear Strips T o avoid excessive tunnel wear , tunnel wear strips must be installed whenever track studdin g is used. See your dealer for more information. W ear strips are designed for a specific stud length. See your dealer's studding chart for recommended traction accessories. Components (viewed from re[...]

44 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessorie s on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

45 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See P age Drive Belt Condi tion 91, 94 Steering Syste[...]

46 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of prop er operation. Read and Understan d Y our Owner's Manual Read the Owner's Manual completely and refer to it[...]

47 PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic Brakes Always check the following items fo r proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer [...]

48 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Y our snowmobile may have a parking brake lever lock located over the brake lever . Use the brake lever lock only when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brak[...]

49 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. n T rack Use of traction products [...]

50 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile p rotects the operator from mov ing parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that th e hood straps ar e in good condition a[...]

51 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine S top 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 th e ignition switch is turned to OF F . n Lighting Check the headlight (hig h and low beam), t[...]

52 OPERA TION Starting the Engine 1. T urn the fuel valve on. See page 57. 2. T urn 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 CHOKE . Do not use the choke if starting a warm engine. NOTE: Do not depress the throttle until the engine starts. 5. If eq[...]

53 OPERA TION 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 gal- lons of fuel. This, in addition to th e lubrication supplie d by the injection system, will assure prope[...]

54 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 59. Oil Recommendations This snowmobile is equipped with a variab le exhaust system (V ES). Engine lubrication comes from oil ad ded to the fuel and oil injection systems. Polaris recommends the us e of VES II 2 Cycle Oil for this engine. [...]

55 OPERA TION T rack W arm-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 trac k should be about 4 I (10 cm) of f the ground. 2. S tart the engine and allow it to warm up two to three minutes. 3. Depress the thro[...]

56 OPERA TION Slide Rail and T rack Cooling Fu e l CA UTION Inadequate cooling and lub rication will lead to overheating of the slide rail and track, resulting in premature w ear and failure. Reduce speeds and fre- quently drive into fresh snow to allow adequ ate cooling and polishing of the slide rail and track surfaces. Avoid oper ating on ice, h[...]

57 OPERA TION Fu e l F uel V alve T urn the fuel valve clockwise to OFF to shut off the fuel supply . T urn the valve counter-clockwise to ON to turn the fuel supply on. F uel Recommendations Y our Polaris en gine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal of variability in the qu[...]

58 OPERA TION Fu e l F uel Reserve Capacity (Mechanical Gauge) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. F uel System Deicers If you use non-oxygenated fuel, Polari s recommends the regular use of isopropyl-based fuel system d eicer . Add one to two ounces per gallon (8-16 ml per liter) o[...]

59 OPERA TION n Oil Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss of pumping action, which could result i[...]

60 OPERA TION Carburetion Proper carburetor adjustment is c ritical. A lean mixture (too muc h air , too little fuel) may result in piston bu rning, 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 thin gs like fuel[...]

61 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e af fect air density , which is the amount of oxygen available for com bustion. In low elevations and cold temperatures, the air has more oxygen . In higher elev ations and high er temperatures, the air is less dense. The carbure tors are calibrated for a n a ltitude o[...]

62 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( + ) to ground out the ig nition 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 engi ne whenever all pressure is removed from the throttle lever and the throttl[...]

63 OPERA TION Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switch to OF F . 2. V isually inspect the throttle cable and carburetor to determine what caused the safety switch to activate. 3. T est the throttle lever by compr essing and releasing it several times. The lever and cable must retu[...]

64 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 62 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine[...]

65 OPERA TION Reverse Operation Electronic R everse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of o ver 6000 feet, adjust the igni- tion setting as described on page 67. Al ways make sure the vehicle is stopped and the engi ne is running at idle before shifting to rever[...]

66 OPERA TION Reverse Operation Electronic R everse (PERC t ) Engaging Reverse 1. S top the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse but- ton ( + ) on the left-hand con- trol for one second, then release. The engine will auto- matically reduce RPM and start a reverse rot[...]

67 OPERA TION Reverse Operation Electronic R everse (PERC t ) Disengaging Reverse 1. S top 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 transmis[...]

68 OPERA TION Daily Storage At the end of each ride, park the snow- mobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) of f the ground. Remove the ke y and cover the machine.[...]

69 OPERA TION To w i n g Do not use the fr ont bumper to pull or dr ag the snowmobile. The fro nt bumper is not designed for this type of use and may deta ch from the vehicle if force is applied. For your safety , do not attempt to use a tow hitch until you've read the following warnings and understand the p roper hitch functions. If the snowm[...]

70 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Y our snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- [...]

71 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty , and read the maintenance section of your owner's manual. Y ou are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an auth orized Polaris dealer to [...]

72 MAINTENANCE P olaris Recommended Mainte nance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 130. The recommended maintenance schedul e on your snowmobi[...]

73 MAINTENANCE P eriodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten, [...]

74 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e 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 -- II II Fluid Leaks -- II II Brake Pads 86 II II Brake Disc -- II II Parking Brakes 48 II II Brake System 47, 86 I Brake Fluid 87 R FUEL MANAGE[...]

75 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I Ste[...]

76 MAINTENANCE Lubrication Suspension and Steering Lubricate the suspension and steer ing components with Polaris Pre- mium All-Season Grease at 500 mile s (800 km) and annually or every 1000 miles (1600 km) thereafter . A gr ease gun kit, comple te with grease and adaptors, is available to lubri cate all fittings on Polaris snowmo- biles. See page[...]

77 MAINTENANCE Lubrication EDGE 136 Rear Suspension Driveshaft Bearing Inject grease into th e fitting on the speed- ometer sensor housing until grease pur ges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. [...]

78 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at th e intervals outlined in the mainte- nance charts beginning on page 72 . Change the chaincase oil after the first 500 miles (800 km), then every 10 00 miles (1600 km) or season- ally . Maintain the oil level between the “safe” marks on the dipstick. Clea n the magneti[...]

79 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plug fouling and carbonization. Refer to y our Owner's Manual Supplement for th e specific spark plug to be used in your machine. Spark plug condition is indica[...]

80 MAINTENANCE Spark Plugs Normal Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip shou ld not be white. A white ins ulator tip indicate s over- heating, caused by [...]

81 MAINTENANCE Intake Filters The intake foam filter ( + ) limits snow ingest ion into the intake system. When operating in loose powder snow , check the top of the foam filter periodically to remove any accumulation o f snow . NOTE: These illustrations are general representations. Y our model may differ . CA UTION Operating the snowmo bile with th[...]

82 MAINTENANCE F uel Filter/F uel Lines The fuel filter is locat ed inside th e fuel tank. This component requires no maintenance. Inspect the fuel lines re gularly for signs of deteriorat ion or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fue l compounds may occur . Replace worn or dam[...]

83 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 correc t for your elevation. It's your dealer's responsi bility to make sure the correct main jet is installed. Carburetor Adjustments The frequency at which the carburetor s are s[...]

84 MAINTENANCE Carburetor W ater/Sediment T rap Service Most Polaris snowmobiles contain pa tented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, consisting of a hose with a plug, sh ould be drained at least every 2000 miles (3200 km) and inspected for contamination. 1. T urn the fuel tank supply valve o[...]

85 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). T o inspect, allow the engine and exhaust system to cool completely . Open the hood an d inspect the muf fler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. Drive Chain T ension T[...]

86 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 47. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ). A kit is available for replacing brake pads. S ee your dealer . Excessive Lever T ravel Hydrauli[...]

87 MAINTENANCE Brakes Brake Fluid On some models , the brake fluid le vel can be seen through a plastic sight glass in the brake reservoir . If the fluid is suff icient, the sight glas s will be black. If the sight glass is an y color other than black, add brake fluid. On all other models, frequently check the re servoir to be sure it contains the [...]

88 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as leve l as possi- ble. The reservoir must be in this po sition to minimize the possibility of air entering the s[...]

89 MAINTENANCE Lights Headlight Adjustment The headlight may be a djusted for ve rtical aim using the following pro- cedure. 1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floo r to the center of the headlight and make a mark on the wall. 3. S tart the engi[...]

90 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causin g a hot spot that will shorten the life of the lamp. If fingers do touch the bu lb, clean it with an alcohol- moistened towel. Headlight Bulb Replacement 1. Pinch the en ds of the spring (1) together and lift until it releases from the [...]

91 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment offset i s import ant for maintaining optimum perfor- mance. Please see your Polaris dealer if you experie nce a de[...]

92 MAINTENANCE Clutch System Drive Belt Removal 1. S top the engine after operating in a forward motion. 2. T urn the ignit ion key off. W ait fo r the engine to stop completely . 3. Lock the parking brake (if equipped). 4. Open the hood. 5. Remove the clutch guard retain- ing pin and open the clutch guard. 6. Locate the L-wren ch in the tool kit a[...]

93 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: T o ensure satisfactory belt life, install belts so they operat e in the same direction of rota- tion by positioning the identification numbers so that you can re ad them. If required, sepa- rate the sheaves as outlined i[...]

94 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply do wnward pressure while measuring at point 2. This measurement should b e 1 1/4 inches (3.2 cm). Drive Belt Adjustment Belt deflection can be adjusted with out r[...]

95 MAINTENANCE Clutch System To r q u e S t o p If your snowmobile is equipped with an engine torque st op, periodi- cally check torque stop clearance. W ith clutches in proper alignment, the torque stop clearance should be .010 I -.030 I (.25-.75 mm) from the engine case. Adjust if necessary , and lock the jam nut. Reverse Maintenance If your snow[...]

96 MAINTENANCE Chain T ension Maintain the proper chain tens ion as outlined on page 85. F all T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and tr ained service technician will keep your machine in peak oper ating condition. To o l K i t A tool kit is included with each machine for [...]

97 MAINTENANCE Tr a c k T rack Inspection 1. Using a hoist, safely lift and support the rear of the snow- mobile of f the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track along the entire length of each rod ( + ). Bend the track to check for breakage. 4. Replace the track if any rod damage is found. T rack Lub[...]

98 MAINTENANCE Tr a c k T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments should be ma de only after the track is warmed up and lim ber . 1. T urn the engine off. 2. Lift the rear of the machi ne and safely support it of f the ground. 3. Place the recommen[...]

99 MAINTENANCE Tr a c k T rack T ension 4. Check for specified slack between th e wear surface of the track clip and the plastic slider . Refer to the T rack T ension Data Chart on page 98. If the track needs adjustment: 5. Loosen the rear idler shaft bolts. 6. Loosen the locknuts. 7. T ighten or loosen the track adjusting screws to provide equal a[...]

100 MAINTENANCE Tr a c k n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track of f the ground. 2. S tart the engine and apply a small amount of throttle unt il the track tu[...]

101 MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any poin t along their length. Failure to do so may result in per- manent damage to the track o[...]

102 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with veh icle weight compressing the suspension, measure from the straight e dge of the skis at the center of the sk i mounting bolt. The measurement between the skis at po int X should be 1/8 I to 1/4 I (3-6 mm) greater than the measurement at poi[...]

103 MAINTENANCE Steering System n Ski Skags Check skags before each use of the snowmobile to ensu re positive steer- ing characteristics. Skags must be replaced when worn to half their orig- inal diameter . NOTE: Carbide skags must b e replaced if any abnormal wear or chip- ping is found. Skag Replacement 1. Raise and su pport the front of th e mac[...]

104 MAINTENANCE Battery Battery Fluid A poorly maintained battery will de teriorate rapidly . Check the battery fluid level often. Maintain the flui d level between the upper and lower level marks. Battery Connections Keep battery terminals and connectio ns free of corrosion. When clean- ing is necessary , remove the corrosion with a stiff wire bru[...]

105 MAINTENANCE Battery Battery Removal 1. Disconnect battery hold do wn straps. 2. Remove battery vent tub e from battery . 3. Disconnect black (negative) battery cable first. 4. Disconnect red (positive) battery cable second. 5. Carefully lift the battery out of the snowmobile. Do not tip it side- ways or spill electrolyte. WAR N I N G Improperly[...]

106 MAINTENANCE Battery Battery Installation 1. Place the battery in its holder . Attach the hold down strap. 2. Install the battery vent line. It must be free from obstructions and securely installed. Route the vent line prop erly to prevent kinks and to allow for proper drainage. 3. Connect and tighten the red (positive) cable first. 4. Connect a[...]

107 MAINTENANCE Battery Battery Storage When your snowmobile is place d in storage for one month or more: • Remove the battery . • Char ge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly . Before using the battery , take it to yo ur dealer for testing and re charging. Batteries may freeze if not fully c[...]

108 MAINTENANCE n Pre-Ride Suspensio n Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems. Check the follow- ing items on a weekly basis or before any long trip: n Check suspension moun tin[...]

109 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many componen ts. See page 1 13 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chass[...]

110 MAINTENANCE Extended Storage Bearings Grease the drive shaft clutch side bearing with Polaris Premium All- Season Grease or a similar high qu ality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. T o prevent oxida- tion on the clutch sheaves, lubricate the sheave faces of the drive an[...]

111 MAINTENANCE Extended Storage Engine and Carbur etor Protection Using a fuel stabilizer and topping of f the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the fol- lowing procedure 1. T ransfer unused fuel from the fuel tank to an ap proved fuel con- tainer using a siphon pump. Do not re-use fu[...]

112 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack conn ector blocks with dielectric grease and re-connect . Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured awa y from sharp edges, steering li[...]

113 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (ga l.) 2872[...]

114 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if tec hnical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • Disa ssemble drive clutch to inspec t shift weights for wear [...]

115 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jacks haft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or repla[...]

116 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spa rk. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. See page 52. • Make sure f[...]

117 TROUBLESHOOTING EDGE 136 Suspension Problem Solution Rear suspension bottoms too easily • Increase torsion spring preload • Increase rear shock compre ssion damping by turning screw clockwise • Increase torsion spring wire diameter (see your dealer) • Rotate RRSS to a higher position. See page 39. Rides too stiff in rear • Check for b[...]

118 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at highe r RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the ma chine in extremely cold weather and warm it up. Break machine loose fr[...]

119 WA RRANTY Service and W arranty Information Obtaining Service and Warranty Assistance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Cont act your Polaris dealer for replacement parts, service or warranty . Y o ur dealer receives freque nt updates on cha nges, modifications and tips on sn[...]

120 W ARRANTY Service and W arranty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monito ring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft . A. In addition to notifying the prop er law enforcement officials, the ow[...]

121 WA RRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Polaris snowmobile against defects in material or workmanshi p. This warranty covers the parts and labor charges for repair or replacement of d efective parts t hat are cove red by this warranty . [...]

122 W ARRANTY Limitations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some s[...]

123 WA RRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to d elivery ma[...]

124 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontract is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promot ion. Th e free Second Y ear E ngine Service Contract is honored by all authorized Pola ris sn[...]

125 WA RRANTY Polaris Second Y ear Engine Service Contract Coverage Coverage for second year en gine failures due to defects in materials and workmanship will be determined by Polaris in its sole di scretion. Coverage is automatic with no addi- tional paperwork required. The free Second Y ear Engine Servic e Contract is subject to a $50 deductible [...]

126 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

127 WA RRANTY Exported V ehicles How to Get Service In the Country where you r vehicle was purchased: W arranty or Service Bulletin repairs must be done by an authorized Polaris d ealer . If you move or are traveling within the country wh ere your vehicle was purchased, W arranty or Service Bulletin repairs may be requested from any authorized Pola[...]

128 W ARRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine em issions limited warranty is in addition to the Polaris standard limited warra nty for snowmobiles. Polaris Industries Inc. warrant s that at the time it is fi rst purchased, this emissions- certified snowmobile engine is designed, built and equipped so it conform[...]

129 WA RRANTY Snowmobile Engine Emis sions Limited W arranty This limited warra nty excludes failures not caused b y a defect in materia l or workmanship. This limited warr anty does not cover damage due to accidents, abuse, or improper handling, maintenance or use. This limi ted warra nty also does not cover any engine that has been structur ally [...]

130 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wi th an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi[...]

131 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

132 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

133 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 44 Air Box Warning . . . . . . . . . . . . . . . 22 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Altitude Setting, Reverse . . . . . . . . . 67 Avalanches . . . . . . . . . . . . . . . . . . . . 14 B Backrest . . . . . . . . . . . . . . . . . . . . . . 28 Battery . . . . . . . .[...]

135 INDEX I Ice and Snow Build- up . . . . . . . . . . . 15 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 IFS Adjust ments . . . . . . . . . . . . . . . . 29 IFS Components . . . . . . . . . . . . . . . . 29 Inadequate Snow Conditions . . . . . . 19 Intake Filters . . . . . . . . . . . . . . . . . . . 81 Intake Silencer . . . . . . .[...]

136 INDEX S Steering Inspection/Adjustment. . . 101 Steering Lubrication . . . . . . . . . . . . 76 Steering System . . . . . . . . . 49, 101-103 Stopping, Emergen cy . . . . . . . . . . . . 64 Storage, Daily . . . . . . . . . . . . . . . . . 68 Storage, Extended . . . . . . . . . . 109-112 Studs . . . . . . . . . . . . . . . . . . . . . . . . 41 S[...]