Polaris FS IQ TOURING 7427 C manual

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W ARNING Read, understand, and follow all of the in structions and sa fe ty precau tions in this manual a nd on al l product lab els. F ailure to follow the safety precautions could result in serious injury or death. W ARNING The engine exhaust from this product co ntains chemicals known to the State of California to cause cancer , birth defects or[...]

1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly pro duce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a ll [...]

2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks of Pola ris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2007 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 an[...]

3 T A BLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmatio n for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner ’ s ma nual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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5 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when th e snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our mode l may differ . Follow the maintenance program ou[...]

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments acros s the snow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, in clud ing wildlife and vegetation. Snowmobile clu bs and other or [...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation numb ers and key nu mber in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicat ed only by mating a Polaris key blank with o ne of your existing keys, so if both keys are lost, the ignition switch must be replac e[...]

8 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading t he manual. The sa fety alert symb ol , on your vehicle or in this manual, alerts you to the potential for in jury[...]

9 SAFETY Operator Safety Follow the recommended m aintenance prog ram outlined beg inning on page 99 of this manual to ensure that all critical co mponents on the snowmobile are thor oughly inspected by your dealer at specific mileage intervals. WA R N I N G Driving a snowmobi le requires your ful l attention. DO NOT drink alcohol or use drugs or m[...]

10 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a rev o lving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments w ith the en gine running. T urn off th e igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then resta[...]

11 SAFETY Operator Safety Riding P osition Operating a snowmobile requires sk ill and balance for proper control. Rider positions may vary with expe rience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hand s on the handlebar grips fo r proper throt tle, brake and steering control. Sur[...]

12 SAFETY Operator Safety Riding Apparel 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 established safety standards. Approved helmets in the USA and Ca na da bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania[...]

13 SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only . A decal on the console of these mode ls indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles ar e designed for up to two riders. A deca l on the hood of these models indicates that the vehicle is designed for [...]

14 SAFETY Operator Safety Disabled Operators Safe operation of th is rider -active vehi cle requires good jud gement and physical skills. Cargo Overload T oo much weight on the rear of th e 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 carr[...]

15 SAFETY Operator Safety Excessive Speed Always observe all stat e and local laws govern ing snowmobile opera- tion and speed limits. Al ways be alert and pay attention to t he trail ahead. If your speed is 40 MPH (64 km/h), your sn owmobile is traveling about 60 feet (18 m) p er second. If you lo ok back for only two seconds, your snowmobile will[...]

16 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 disti[...]

17 SAFETY Operator Safety Avalanches Snowmobilers should always be p rop erly trained and equipped before traveling in mountainous terrain: • T ake an aval anche cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each pers on is equipped with a shovel, probe and avalanche beacon. Y ou don’t have to be snow[...]

18 SAFETY Operator Safety I ce 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, remo ve ice and snow build -up that may be obstructing the steering linkage. NOTE: If you r snowmobile i s equipped wi th RIDER S[...]

19 SAFETY Operator Safety Driving on Slippery Surfaces Driving in Hilly T errain Use extra caution when operating in hi lly 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 snowmobile to maintain proper balance and avoid possible rol love[...]

20 SAFETY Operator Safety Drive Belt Do not operate the engine w i th the drive belt r emoved. Any servicing that requires operation without a belt must be performed by your dealer . Operation of the engin e 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 filt[...]

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubr ica tion for the power slide suspension and, on liquid co oled models, coo ling for the engine, adequate snow cover is a requirement for operation of y our snowmobile. Driving in to o little snow will result in excessive we ar and damage to the slide rail, track [...]

22 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile con di- tions may become dangerous if operators drive improperly . If you’re new to snowmobiling, acquaint your self with the machine and with what it will and won’ t do under various conditions. Even seasoned driv- ers should spend som[...]

23 SAFETY Operator Safety Windchill/T emperature Charts The following information is provided to help you determine when tem- peratures be come da ngerous for riding. WIND CHILL CHART ( ° F) WIND CHILL CHART ( ° C) Wind Speed in MPH Actual Thermometer Readi ng ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperat[...]

24 SAFETY Safety Decals and Locations W arning decals have been pl aced 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 a ny of the decals depicted in this manual differ from the decals on your snow mobile, always read and follow the instructions of the de[...]

25 SAFETY Safety Decals and Locations “No P asseng er” W arning Snowmobiles designed for a single rider only have a warning decal on the left console: W ARNING This vehicle is design ed for operator o nly . “NO P A SSENGER” P assenger W arning Snowmobiles designed for an operator and one passenger have a warning decal on the left console. F[...]

26 SAFETY Safety Decals and Locations Reverse W arnin g Polaris snowmobiles equipped with el ectric reverse and will have this decal o n the cons ole: W ARNING Reverse operation, even at low speeds, can cause loss of control resulting in seri ous injury or death. T o avoid loss of control, always: • Look behi nd before and wh ile backing up . •[...]

27 SAFETY Safety Decals and Locations Operation W arning An operation warning decal is pres ent on the console of all Polaris snowmobiles: W ARNING • T o avoid seri ous injury or death, read an d understand all warning s and the Owner’s Manu al before operat ion. If manual is missing, con- tact a Polaris dealer for a r eplacement. • This vehi[...]

28 FEA T URES 1. Nosepan 2. Skis 3. Fr ont Bumper (d o not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Storage Compa rtment or Cargo Bag 8. Operator Seat 9. P assen ger Seat 10. Backrest 11. P assenger Grab Handle 12. Grab Ha ndle Heater Switch 13. T aillights 14. Rear Bump er 15. Snow Flap 16. T rack 17. Suspe[...]

29 FEA TURES 1. MFD Display 2. Mirrors 3. Rider Select t 4. F uel Filler C ap 5. Handleba r 6. Hood Hold Down Straps 7. Hand lebar Grip W armer Switch 8. Thum bwarmer Switc h 9. Electr onic Rever se Button 10. M FD Contro l 11. Headlight Dimmer Switch 12. Parking Brake Lock 13. Brake Lever 14. Engine Stop Switch 15. Thr ottle Cont rol 16. M-10 ACE [...]

30 FEA T URES Backrest The backrest is adjustable for either operator or passenger use. See page 32 for passenger seat installation instructions. 1. Loosen the upper adjustment knobs to rais e or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- ward for passenger use. 3. Always tighte[...]

31 FEA TURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to r aise the headlight beam. Radiator Compartm ent Access P anel The access panel is provided for cle aning debris from the radiator . Cargo Bag (T ouring) The carg o bag is secured to the rear of the tunnel with straps. The[...]

32 FEA T URES T runk/P assenger Seat/Cargo Bag (Cruiser) The trunk co ver is removable to allow installation of the passe nger seat and cargo bag. The maximum weight capacity for the cargo car- rier is 30 lbs. (14 kg). Always secure cargo before operating. Do not exceed the carrier weight limit. Do not allow a passenger to sit on the seat back or t[...]

33 FEA TURES P assenger Grab Handle On some models the position of the passenger grab handles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab handles. 2. Rep osition the grab hand les to one of the three available posi- tions on the grab handle tube between the operator seat and the passenger sea[...]

34 FEA T URES RIDER SELECT Adjusta ble Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions. WA R N I N G If your snowmobile has five adjustme nt positions, do not remove[...]

35 FEA TURES RIDER SELECT Adjusta ble Steering System Choosing the Best RIDER SELECT Position P osition Riding Style 1 2 3 Relaxe d T rail Ri ding Rider weight is slightly behind the center of the snowmobi le for comfortable a nd relaxed riding. 4 5 General T rai l Riding , Boondo cking, Deep Snow Riding Rider weight is centered on the snowmo- bile[...]

36 FEA T URES RIDER SELECT Adjusta ble Steering System 1. Stop the sn owmobile. 2. Press the releas e button and move the handlebar forward or rearward to the desired position. WA R N I N G Attempting to adjust the handlebar posi tion while the sn owmobile is moving could result in loss of control and serious injury or death. Always stop the snowmo[...]

37 FEA TURES Engine Manage ment System Malfunction Indicator Lamp (MIL) Illuminated MIL The MIL (Check Engine Indicator) will illuminate when a problem with engine management system components is detected. 1. T urn the engine off and restart it. If the light goes off, continued operation is permissible. 2. If the light illuminates again, determine [...]

38 FEA T URES Engine Manage ment System T o protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (if eq uipped) if the f ollowing condi- tions are encountered. Under extr eme overheating conditions, the sys- tem will also stop the engine en tirely to prevent engine damage. V ehicle Speed is Limited En[...]

39 FEA TURES Engine Manage ment System The engin e management system is pr ogrammed to alert the rider when coolant temperatures reach higher -t han-normal levels. The system responds by taking the following sequential steps to alert the rider . 1. The High T emperature In dicator on the MFD will flash. T o cool the engine, drive the snowmob ile in[...]

40 FEA T URES Knock Sensor (T urbo Models) A knock senso r monito rs th e engine and respo nds to detonati on by auto- matically reducing the engine timing and ad ding fuel. This results in decreased engine RPM and performance. NOTE: Engine p erformance will be red uced if fuel with a lower octa ne than 91 is used. See fue l recommendatio ns on pag[...]

41 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Anal og Gaug e 2 Digital Gaug e 3 Check Engine Indicator 4 High T emp Indicato r 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System V oltage Level (all models) and M[...]

42 FEA T URES Instrumentation MFD Settings The MFD control switc h allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specif ic inst ructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off. If the engine is off,[...]

43 FEA TURES Instrumentation MFD Settings Speedometer/T achometer The speedometer and tachometer ca n be viewed in either the analog or the digital display . If the analog disp lay is set to show speedometer read- ings, the digital screen will automati cally display the t achometer (option 1). If the analog is set to show th e tachometer , the digi[...]

44 FEA T URES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and Hist ory . Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycl e through the program’ s screens. P erform[...]

45 FEA TURES Instrumentation MFD Digital Display Programs P erformance Program T r ip Settings T rip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank. The T rip F o[...]

46 FEA T URES Instrumentation MFD Digital Display Programs P erformance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4. When the hour starts flashing, press the SET switch once to advance on e hour . NOTE[...]

47 FEA TURES Instrumentation MFD Digital Display Programs Engine Pr ogram Press and release the MODE button until the engine program screen is active. The default display for this scr een includ es engine hours, electri- cal system voltage level, fuel level (if equippe d) and either engine cool- ant temperature, air temperature (accessory) or altim[...]

48 FEA T URES Instrumentation MFD Digital Display Programs Engine Pr ogram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. NOTE: Press and hold the MODE switch for ten seconds to switch betw een standard and[...]

49 FEA TURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cy cle through the Maximum V ehicle Speed, Maximum Engine RPM and Se[...]

50 FEA T URES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the[...]

51 FEA TURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder T o r eset the r eminder at a new interval: 1. Enter th e History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for fiv e seconds, until the hours begin to flash. Immediatel[...]

52 FEA T URES Instrumentation MFD Digital Display Programs M-10 ACE Suspension Adjustments (Cruiser) A switch on the console (above the ignition switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. See page 69 for instructions. MFD Battery Replacement Models equipped with the clock feature have a battery to power the cl[...]

53 FEA TURES Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the batte ry holder . Pull the battery out gently . NOTE: The battery will not come out of t he holder un less the leading edge of the battery is raised. Hold the battery compartm[...]

54 THE PERFECT FIT IQ F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for approx imately 150 miles (240 km) before making any fine-tun ing adjustments. Settings will vary from ri der to rider , depending on rider weight, vehicle speed, riding style, an d trail conditions. W e recommend starting with factory[...]

55 THE PERFECT FIT IQ F ront Suspension Adjustments F ront Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris de aler for assistance before attempt- ing to adjust preload. Increasing the spring preload too mu ch may adversely affect the han- dling of the snowmobile and the [...]

56 THE PERFECT FIT IQ F ront Suspension Adjustments Shock V alving The shocks can be revalved if spring preload alone isn't suf ficient and further adjustment is desired to control suspension stif fness. F ront Springs The front sprin g rates can be adjusted by changing the ni trogen pressure. The upper chamber adjusts the main spring rate. Th[...]

57 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail co nditions, 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 sus- pension designs and adjus tments involv e a compromise, or tr [...]

58 THE PERFECT FIT IQ Rear Suspensi on Adjustments Initial Spring Preload Setting (Sag Method) T o set up the 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 sus pension at full extension. NOTE: The rear bumper may ne[...]

59 THE PERFECT FIT IQ Rear Suspensi on Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Different [...]

60 THE PERFECT FIT IQ Rear Suspensi on Adjustments Suspension Coupling On all Polaris snowmobile rear susp ensions, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension cou pling, these torque ar ms could move inde pendently of each other . Rear suspension cou pling links the movemen t of the f[...]

61 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) 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 indepen- dent moveme nt between the rear to rque and the front torq ue arm. Adjusting the RRSS either al[...]

62 THE PERFECT FIT IQ Rear Suspensi on Adjustments W eight T ransfer During Acceleration The preferred method for controlling weight transfer during acceler ation is by adjusting the rear rear sc issor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner-[...]

63 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments The M-10 suspension has been design ed to be very sensitive to rider weight. Changes in rid er weight of 25 lbs. (1 1 kg) or more might requ ire appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential[...]

64 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings 1. T o check sag, raise the rear bu mper until the suspension is fully extended (the rear shock will no t extend any further). Measure the distance from the ground to the bo ttom of the bumper (dimension X) as shown in the illustratio n. Record the measur[...]

65 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings FRA P osition The FRA setting is the primary rear su spension adjustment . It will have the MOST ef fect on the rear suspension performance. T o adjust the FRA: 1. Refer to the initial set-up refere nce chart (see page 68) to de termine the desired FRA po[...]

66 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA positi on alone does not allow the setu p of the proper amount of sag, the center retainer of the rear track shock can b e replaced with optional retainers to adjust the prel oad and change the sag. See your Polaris dealer for a[...]

67 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum bala nce between ride and handling. If a rider prefer s more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount. 1. [...]

68 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. The re are also two front arm mounting holes in the slide rail that can a djust ski pressure. The lower hole increases ski pressure while the upper h ole decreases ski pressure . NOTE: By design, the BIASED COUPLE des ign of the M-10 suspe[...]

69 THE PERFECT FIT F AST M-10 ACE Rear Suspension Adjustments MFD Suspension Adju stments (Cruiser) A switch on the console (above the ignit ion switch) allows you to adjust the M-10 ACE suspension with the MFD control switch. NOTE: The engin e must be running to make suspension adj ust- ments with the MFD control sw itch. 1. Place the console rock[...]

70 THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adju st handlebar position. See page 34. Use the follow ing steps to adjust handlebar angle at the handlebar block. 1. Remove the handleba r cover to expose the handlebar and the four adjuster block bolts. 2. Usin g a 7/16" wrench, loose n the four nuts on the bottom of t[...]

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

72 THE PERFECT FIT T raction Products Studs Before equipping yo ur snowmobile wi th traction produc ts, be awar e of the laws in yo ur area pertaining to the use of traction products. Use only Polaris tractio n products on yo ur snowmobile. T rack warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installati[...]

73 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 to prevent ski wear caused by contact with roads and other bare terrain. Us e carbide skags with studded tracks to help maintai n proper vehicle steering and con trol. See page 145. If your [...]

74 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 re fer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspect ion items. Item See P age Drive Be lt Condition 135 Steering System[...]

75 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 proper operation. Read and Un derstand Y our Owner's Manual Read the Owner's Manual completely and refer to it [...]

76 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the sn owmobile protects the op erator from moving parts as well as aiding in sound e mission control and other functio ns. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that th e hood straps are in good condition a[...]

77 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items fo r proper operation before starting the engin e. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip th an 1/2" (1.3 cm). A smaller distance indicates low brake fluid le vel or a ir in the hydraulic system. Refer to[...]

78 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Use the park ing brak e lever lock only when you want the sno wmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Rese rvoir/Cover 4. Fluid Level Indicato[...]

79 PRE-RIDE INSPECTIONS Before Starting the Engine n T rack Inspection NOTE: T rack dama ge or failure caused by o peration on ice or poo r lubrication conditions voids the track warranty . WA R N I N G Operating the sno wmobile with a d amaged track increa ses the possibility of track failure, which could cause loss of control resulting in serious[...]

80 PRE-RIDE INSPECTIONS Before Starting the Engine n Suspension 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. It[...]

81 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine S top Switch Check the auxiliary shut-of f 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 OFF . n Lighting Check the headlight (high and low beam), ta[...]

82 PRE-RIDE INSPECTIONS n Tip-Over Inspections In the event of a tip-over or rollover , check the oil level before operating the snowmobile. NOTE: In th e event of a tip-o ver or rollov er , the engine will stop. T o restart the engine, turn the key to the OFF position, then restart. CA UTION F ailure to check the oil after a tip-over can result in[...]

83 OPERA TION F uel Safety WA R N I N G Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution whene ver handling g asoline. • 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[...]

84 OPERA TION Break-In P eriod The break-in period for your new Po laris snowmobile is the first 500 miles (800 km) of opera tion. No single action on your part is as impo r- tant as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more ef ficient per- formance and longer life for[...]

85 OPERA TION Starting the Engine 1. T urn the key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. Do not apply throttle when startin g the engine unless extremely cold temperatures (below -15 ° F/-26 ° C) prevent the engine from start- ing. NOTE: Under these condi tions, attempt to st art the engine without using t[...]

86 OPERA TION Emergency Starting If the battery is too weak to start th e engine , and a battery charger is not available, the engine can be starte d using jumper cables and a charged battery from an other vehicle. Carefully read and follow the instructions on the following pages. NOTE: If a car or truck battery will be u sed to jump start the snow[...]

87 OPERA TION Emergency Starting 1. Always wear eye pr otection when jump starting your vehicle. 2. Kee p bystanders away from the vehicles. 3. Perform the emergenc y starting procedure in a well-ventilated area. 4. Position the vehicles close enough for the jumper cables to reach easily between the batteries, but do not allow the vehicles to touch[...]

88 OPERA TION Emergency Starting 12. Make sure that the engine st op switch is in the UP position. 13. Attempt to start the vehicle. 14. If the engine does not turn over (crank over), wait 30 to 60 seconds and attempt to start the engine agai n. If the engine does not start, wait another 1 to 2 minutes and atte mpt to start the engine again. 15. If[...]

89 OPERA TION Fu e l For peak performa nce, Polaris recomm ends the use of 91 oc tane or higher fuel. Alth ough 87 octane fuel is usable, some engine perfor- mance will be lost and fuel econ omy will decrease. Do not use lower than 87 octane fuel. Do not use fu el containing mo r e than 10% ethanol (including E85 ) . Fu e l L e v e l The fuel symbo[...]

90 OPERA TION T rack W arm-Up WA R N I N G A loose track or flying debris could caus e serious injury or death. Stand clear of the front of the ma chine and the moving track. Never ho ld the snowmobile up or stand behind it whil e warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging. Be sure the rea[...]

91 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 approximately 4" (10 cm) of f the ground. 2. Start the engine and allow it to warm up two to three minutes. 3. Depre[...]

92 OPERA TION n Engine Stop Switch Push down on the engine stop switch to ground ou t the ignition an d stop the engine quickly . Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is design ed to limit engine speed to 2400 RPM whenever all pressure is remo ved from the throttle lever and[...]

93 OPERA TION n Throttle Lever If the engine speed limits at 2400 RPM when the throttle lever is released: 1. T urn the ignition switch to OF F . 2. V isually inspect the throttle cabl e and throttle body 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[...]

94 OPERA TION Electronic Reverse (PERC 4 t ) Electronic reverse will ac tivate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum vehicle speed when oper- ating in reverse wil l be approximately 12 MPH (19 km/h). Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmobi[...]

95 OPERA TION Electronic Reverse (PERC 4 t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button fo r one second and release . The light on the instrument panel will shut off. 3. Apply the throttle slowly to make sure the transmission is in for- ward. n Emergenc y Stopping The following chart li[...]

96 OPERA TION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and supp ort it at the rear with an appropriate track stand. The track should be susp ended approximately 4" (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g Do not use the f ront bump er to pull or drag the snowmobi le. Th[...]

97 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control device s 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-[...]

98 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty on page 166, and read the maintenance section of your ow ner's manual. Y ou are responsible for ensuring that the specified maintenance is per- formed, including the emission-rela ted maintenance outlined in t[...]

99 MAINTENANCE P olaris Re commended Maintena nce Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance L og beginning on page 168. The recommended maintenanc e schedul e on your snowmob[...]

100 MAINTENANCE P eriodic Maintenance Interval T able O = Perfor m Serv ice X = Replace DAIL Y or PRE-RID E INITI ALL Y Miles (km) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Stop Switch 81 T est for proper operation. Do not operate if switches fail, see your dealer for ser- vice. O[...]

101 MAINTENANCE P eriodic Maintenance Interval T able O = Perfor m Serv ice X = Replace DAIL Y or PRE-RID E INITI ALL Y Miles (k m) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Coolant Hoses -- Inspect, replace if worn or damaged OO O Heat Exchangers -- Inspect, replace if damaged OO O F u [...]

102 MAINTENANCE P eriodic Maintenance Interval T able O = Perfor m Serv ice X = Replace DAIL Y or PRE-RID E INITI ALL Y Miles (km) YEARL Y or EVERY Miles (km) Item Pg Instructions (see referenced pages) 150 (240) 500 (800) 1500 (2400) Engine Mounts -- Inspect, replace if worn or damaged OO Spark Plugs 117 Inspect condition/gap, replace as needed OO[...]

103 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance T able beginning on page 10 0. Always change the oil filter whenever changi ng oil. See page 151 fo r the part numbers of Polaris products. P erformance Synthetic 4-Stroke (PS-4) Oil Polaris recommends the use of Perfo rmance Synt[...]

104 MAINTENANCE Engine Oil n Oil Level Check NOTE: Read the entire oil check procedure b efore checking the oil level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. T o obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant tem- perature mu[...]

105 MAINTENANCE Engine Oil n Oil Level Check NOTE: The oil l evel in the oil bottle may d rain below the level of the dipstick if the engine has n ot run for more than a wee k. If you're not sure if there is oil in the system, you must first check to make sure oil is in the sys- tem before checking the oil level. Perform the “Oil in System C[...]

106 MAINTENANCE Engine Oil n Oil Level Check 8. Maintain the oil level in the safe oper ating range, between the upper and lower marks on the dip- stick. If the level is low , add the recommended oil in small increments, about 2 ounc es (60 ml), and recheck the level. NOTE: If the level is low , or when changing th e oil, add only enough oil to bri[...]

107 MAINTENANCE Engine Oil Oil in System Check 1. Position the vehicle on a level su rface. Start the engine and allow it to idle 3-5 seconds (no more than 5 seconds). T urn the engine off. 2. Remove the dipstick. Clean the di pstick with a clean shop towel and reinstall it, screwing it in completely . Remove the dipstick and ver- ify that oil is p[...]

108 MAINTENANCE Engine Oil Oil Change Always change the oil at the interv als outlined in the Periodic Mainte- nance T able be ginning on page 100. Cle an the foam oil brea ther element with each e ngine oil c hange. Se e page 1 12. Always use the re commended oil. Se e page 104, or see your Polaris dealer about oil change kits, whic h contain a ne[...]

109 MAINTENANCE Engine Oil Oil Change 5. Remove the oil return hose from the oil tank. H ave an as sistant place the end of the hose into a drain pan. 6. Disconnec t the 2-pin WHITE/RED and GREEN/WHITE starter motor solenoid control switch harn ess connector located near the battery . 7. Rotate the plug 90 degrees an d reinstall it with the WHITE/R[...]

110 MAINTENANCE Engine Oil Oil Change 18. Remove the oil fi lter cap, then remove the oil filter . Inspect the o- ring and replace it if it's worn or damaged. 19. Install a new filter , then reinstall the cap. T ighten the cap to 18.5 ft. lbs. (25 Nm). 20. Remove the jumper from the starter motor wiring harness. Recon- nect the solenoid and th[...]

111 MAINTENANCE Engine Oil Oil Change 26. Add additional oil to bring the le vel slightly above the lower mar k (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. NOTE: Check the oil level often du ring the fill procedure to avoid ove rfilling. If the filling an d checking pr o[...]

112 MAINTENANCE n F oam Oil Breather Elem ent The foam oil breather element abso rbs small amounts of liquid to pro- tect sensors within the intake system from damage due to oil i ngestion. Check the element before each ride. Clean or replace the breather ele- ment at each engine oil change. Clea n the element if the snowmobile has been tipped on i[...]

113 MAINTENANCE Lubrication 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. W ith the engine off, tu[...]

114 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the P eriodic Maintenance T able beginning on pa ge 100 and before seas onal storage. When opera ting in heavy , wet snow conditions, lubr icate every 500 miles (800 km). Lack of lubrication will adve[...]

115 MAINTENANCE Gearcase Oil n Gearcase Oil Check Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance T able beginning on page 100. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 151 for the part numbers of Polaris products. The dipst ick is lo cated on the lower front side of the gearca[...]

116 MAINTENANCE Gearcase Oil Gearcase Oil Change The drain plug is located on the bottom of the gearcase. NOTE: Polaris does not recommend tip- ping the snowmobil e onto it's side for service. Any time the snowmo- bile is tipped onto it's left side, always check the oil leve l and clean the foam oil breather ele- ment. See page 112. 1. Po[...]

117 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug foulin g due to the preser- vative added durin g the assembly process. A void prolonged idle speeds, which cause p lug fouling and carbon ization. • Use recommended sp ark plugs wit h the proper gap. • Use only resistor -type spark plugs. • T orqu e spark plugs to 1 8-20[...]

118 MAINTENANCE Spark Plugs Normal S park 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 shoul d not be white. A whi te insulator tip indicates ov erheating, caus[...]

119 MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loos e powder snow , check the top of the foam filter periodically to remove any accumulation o f snow . F uel Injectors All fuel injector service must be performed by an au thorized Polaris dealer . Do not attempt to clean or servi[...]

120 MAINTENANCE n Alternator Belt Inspection Inspect the alternator belt conditio n and tension before each ride. 1. Stop the en gine. 2. Op en the hood. 3. Inspect the belt for wear , cracks or other damage. If the belt is worn or damaged, install a new belt. 4. Grasp the alt ernator belt an d attempt to twist it. 5. If th e belt rotates 1/4 turn [...]

121 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance T able beginning on page 100. 1. Allow the engine and ex haust system to cool completely . 2. Op en the hood. 3. Inspect the muffler and pipes for crack s or damage. Check for weak or missing retaining springs or damper/s[...]

122 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water . This mixture provi des protection again st freezing. Contact your d ealer if greater protection is requ ired. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with wate[...]

123 MAINTENANCE Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are: • Coolant bottle or overflow tank • Filler neck • Pressure cap • Connecting ho ses Always maintain the coolant level at the “COLD FILL” ma rk on the cool- ant tank (when the engine is cold). C[...]

124 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light The high temperature indicator light will illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. S top the snowmobile and a llow the engine to cool. Place snow on the coolers to help cool the engi ne. If coolant is low in the [...]

125 MAINTENANCE Cooling System Flushing the Cooling System T o ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and disti lled water should be added. Have your Polaris dealer perform this service. Bleeding the Cooling System Bleed the coo[...]

126 MAINTENANCE Cooling System Bleeding the Cooling System 3. Op en the hood. 4. Remove the coolant pressure cap carefully . 5. Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck. Leave the pressure cap off. 6. W ith the cap of f, start the engine and allow it to idle. 7. [...]

127 MAINTENANCE Cooling System Bleeding the Cooling System 9. While observing the bleed return and making sure the coolant level is visible in the filler neck, observe the engine temperature in the digital display . The temperature sh ould rise steadily , indicating that the system is bleeding prop erly . 10. If the temperature does not rise af ter[...]

128 MAINTENANCE Drive Chain T ension Check drive chain tensio n weekly and before each long trip. T o obtain corre ct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake le ver lock, or have an assistant hold the brake lever firmly . 2. Loosen the adjuster bolt jam nut. 3. Finger[...]

129 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve bef ore each use of the snowmobile. See page 77. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, a pproximat ely 1/16" (1.5 mm). A kit is avail- able for replacing brake pa ds. See your dealer . Brake Components[...]

130 MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 151 for the part numbers of Polaris products. The brake fluid level can be seen through the fluid le vel indicator (a plastic sight glass) in the master cyl- inder reservoir . If the fluid is suf fi- cient, t[...]

131 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 snow mobile. During the bleedin g procedure, keep the brake handle as level as possi- ble. The reservoir must be in this position to minimize the possibility of air entering the s[...]

132 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a haloge n bulb with bare finge rs. Oil from skin leaves a residue, causin g a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb , clean it with an alcohol-moistened towel. 1. Remove the plenum cov- ering from the headlight assembly . 2. Lift the rubber b[...]

133 MAINTENANCE Electrical System R E LA Y LA B E L FUSE L A BEL ITEM POWERED ST ART SOLENOID REL A Y Ground side of start solenoid CHAS SIS REL A Y SP ARE 20A None ACCES SORY EMERGENCY SP ARE 30A Accessory pl ugs CHAS SIS 30A High beams Low beams Handwarmers Thum bwarmer T ail lamp Brake l amp Alternator co ils EFI REL A Y EX. SENSOR GA UGE 20A RE[...]

134 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt resi due. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment of fset is import ant for maintaining optimum perfor- mance.Please se e your Polaris dealer if you experience a d[...]

135 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspec t the belt for signs of excessive wear: frayed edges, missing cogs, cracks and exce ssive looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 158. F[...]

136 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility , make sure t he clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave. 2. T u rn the ignit ion key of f. W ait for the engine to come to a complete stop. 3. Lock the parkin g[...]

137 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 th ey operate in the same direction of rotati on by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in t[...]

138 MAINTENANCE T rack Replacement When replacing the track, always inst all a track having the lug size rec- ommended for your model. See your Pola ris dealer . T rack Inspection 1. Using a hoist, safely lift and sup- port the rear of the snowmobile of f the ground . 2. Rotate the track by hand to check for damage. 3. Carefully examine the track a[...]

139 MAINTENANCE T rack Lubrication The slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limite d lubrication, resulting in excessive wear . NOTE: T rack damage or failure cause d by operation on ice or under other poor lubricatio[...]

140 MAINTENANCE T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments shou ld be made onl y after the track is warmed up and limber . 1. T urn the engine off. 2. Lift the rear of the snowmo- bile and safely support it of f the ground. 3. Pla ce the recommended[...]

141 MAINTENANCE T rack T ension 4. Che ck for specified slack between th e wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rea r idler shaft bolt. 6. Loosen the lock nuts. 7. T ighten or loosen the track adjus ting screws as ne cessary to provide equal adjustment on bo th sides of the track. 8[...]

142 MAINTENANCE n T rack Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment w ill cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track of f the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowl[...]

143 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fastener s weekly and before a long ride. T ighten any loose fasteners. + + + + +[...]

144 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the st raight edge of the skis at the center of the sk i mounting bolt. The measurement between the skis at point X should be 1 /8" to 1/4" (3-6 mm) greater than the measurement [...]

145 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 diam eter . NOTE: Carbide skags must be re placed if any a bnormal wear or chipping is found. Skag Replacement NOTE: Some mode ls are equippe d with singl[...]

146 MAINTENANCE Battery Battery Removal 1. Remove the left side panel. 2. Disconnect the battery hold-down strap. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift th e battery out of the ve hicle. Battery Installation When installing a new battery , make su re it's fully char [...]

147 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during s torage and recha r ge as needed to maintain a full charge. NOTE: Battery[...]

148 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a voltmeter or multimeter . A fully charged batt ery will register 12.8 V or higher . 2. If the voltage is less than 12.8 vo lts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater .[...]

149 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 compon ents. See page 151 for the p art numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleanin g, washing, and waxing the hood, chass[...]

150 MAINTENANCE Extended Storage Engine Protection Fogging the engin e is not recommen ded for this model. Electrical Connections Replace worn or frayed electrical wi re and conn ectors. Be sure wiring harness is properly sec ured away from sharp edges, steering linkage, moving parts, and hot ex haust parts. T rack and Suspension Moderate track ten[...]

151 POL ARIS PRODUCTS Part No. Descrip tion Engine Lu bricants 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.) Chaincase Lubr icants 2873105 Synthetic Chainc ase [...]

152 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Speed, RPM or Boost is Limited Engine Doesn't T urn Over Probable Cause Solution Engine Manageme nt System RPM Reduction Mode is activated See causes on page 38. Jammed cl utch Check for twis ted belt or broken spring. See your dealer . Jammed track R emove any fo reign object[...]

153 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine T urns Over , F a ils to Start Engine Backfires Probable Cause Solution Out of fuel Refuel. W ater is present in fuel See your dealer . Old or non-recommended fuel Replac e with fresh recommended fuel. Fouled or defective spark plugs Inspect plugs and replace if necessary . No spar[...]

154 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Runs Irregularl y , Stops or Loses Power Probable Cause Solution Engine Manageme nt System RPM Reduction Mode is activated See causes on page 38. Low battery voltage R echarge the battery to 12.8 VDC. W ater is present in fuel See your dealer . Poor quality or low octane fuel Re pl[...]

155 TROUBLESHOOTING Engine and Drive T rain T roubleshooting Engine Overheating Harsh Drive Clutch Engagement Drive Belt T urns Over Drive System Noise Probable Cause Solution Inadequate snow conditions S top and c ool the engine. Drive into snow frequently to prevent overh eating. See page 21. Low coolant S top and cool the engine. Check the cool-[...]

156 TROUBLESHOOTING IQ Comfort Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper s tatic sag (see page 58). • Change torsion spring to stif fer optional spring (see your dealer). • Rotate RRSS to higher position (see pag e 62). Rides too stiff in rear • Check [...]

157 TROUBLESHOOTING M-10 Suspension T roubleshooting Problem Solution (P erform only one change at a time) Rear suspension bottoms too easil y • Increase FRA position (see p age 65). • Install appropriate opt ional center retainer on rear track shock (see page 66). • Increase front track shock coil spring preload by adding washers. • Revalv[...]

158 TROUBLESHOOTING Drive Belt W ear/Burn Cause Solution Driving a t low RPM Drive at higher RPM. 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 machine in extremely cold weather and warm it up. Break machine loos e from the snow . T owing at low RPM Do not to[...]

159 W ARRANTY Service And W arra nty Information Obtaining Service and W arranty Assistance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warra nty . Y our deale r receives frequent updates on changes, modifications and tips on sn[...]

160 W ARRANTY Service And W arra nty Information P olaris Anti- Theft System The Polaris anti-theft system (P A TS) monitoring p rogram is de signed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A . In addition to notifying the prop er law enforcement officials, th[...]

161 W ARRANTY Limited W a rranty 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 workma nshi p. This warranty covers the parts and labor char ges for repair or replacemen t of defectiv e parts that are cove red by this warranty[...]

162 W ARRANTY Limitations of wa rranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES 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[...]

163 W ARRANTY Conditions and Ex clusions 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 service bulle tins and have the consumer sign the PDI form prior to delivery may[...]

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

165 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 DEA LER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers[...]

166 W ARRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine emi ssions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries In c. warrants that at the time it is first purchas ed, this emissi ons-cer tified snowmobile engine meets current U.S. Environmental Protection[...]

167 W ARRANTY Snowmobile Engine Emis sions Limited W arranty Some states do not allow lim itations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law . This limited warranty excludes failures not ca used by a defect in material or workmanship. This lim- ited warranty doe[...]

168 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 with 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) 1500 mi.[...]

169 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

170 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

171 INDEX A Access Panel, Radi ator Compa rtment 31 Access ories . . . . . . . . . . . . . . . . . . . . 71 Adjust able Steering Sy stem . . . . 34-36 Air Filter (T urbo)) . . . . . . . . . . . . . . 120 Alternator Belt Inspection . . . . . . . . 120 Apparel . . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . .[...]

172 INDEX I Ice and Snow Bu ild-up . . . . . . . . . . 18 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Instrumentation . . . . . . . . . . . . . . 41-53 Intake Filters . . . . . . . . . . . . . . . . . 119 Intake Silence r . . . . . . . . . . . . . . . . . 20 J-K Jump-Starting . . . . . . . . . . . . . . . . 86-88 Knock Sensor (Turbo [...]

173 INDEX S Suspensi on Performance Tips . . . . . . 57 Suspension Set-up Chart, M-10 . . . . 68 Suspensi on, Front . . . . . . . . . . . . . . . 54 Switch Stop Switc h . . . . . . . . . . . . . . . . 92 Suspension Adjustment Switch 30 Throttle Safety Switch . . . . . . . 92 T Throttle Cable Lubrication . . . . . . . 113 Throttle Lever . . . . . . [...]