Polaris Widetrak LX 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 recreational 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 u[...]

2 POLARIS and POLARIS THE W A Y OUT are registered t rademarks of Pola ris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All informa tion 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 compo nents, some minor discrep[...]

3 T A BLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

4 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. When teaching inexperienced operator s to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmo[...]

5 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 [...]

6 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation num bers and key num ber 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 Po laris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replac ed[...]

7 SAFETY Operator Safety The following signal words and symbol s appear througho ut this 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 t he manual. The safety ale rt symbol indicates a potential persona l injury hazard. W ARNING A WARNING indicates a [...]

8 SAFETY Operator Safety Y our Polaris snowmobile is a well- engineered and well-constructed rec- reational vehicle. Follow the reco mmended maintenance program out- lined beginning on page 61 of this manual to ensure that all critical components on the snowmo bile are thoroughly in spected by your d ealer at specific mileage intervals. WA R N I N [...]

9 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 the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then restart[...]

10 SAFETY Operator Safety Survival Preparation For your safety , always ride in a group of other snow mobilers. Always tell someone where you’re going and h ow long you ex pect to be gone. If it isn’ t possible to ride with others , and you must travel into remote areas, always carry survival equipm ent that’ s appropriat e to the co ndi- tio[...]

11 SAFETY Operator Safety Riding Apparel Be prepared, be warm an d be com- fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly . See the cha rt on page 22. Helmet W earing a helmet can prevent a severe head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds es t[...]

12 SAFETY Operator Safety 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 carrier . Disabled Operators Safe operation of th is rider -active vehi cle requires good jud gement and physical sk[...]

13 SAFETY Excessive Speed Observe all state and local laws governing snowmobile o peration. They’ve been estab lished for your prot ection. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approx imate number of feet per second your machine travels . If your speed is 40 MPH, your machine is trave[...]

14 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[...]

15 SAFETY Operator Safety Avalanches Snowmobilers should always be p roperly 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[...]

16 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, check for ice and sn ow build-up that may be obstructing the steering linkage. Snow screens and bi b kits ar e available through y[...]

17 SAFETY Operator Safety Driving in Hilly T errain Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over . If climbing a h ill is unavoidable, keep all your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and av oid po[...]

18 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 engage d, allowing the engine ’ s compression to help slow the machine and keep it fro m rolling freely downhill. Clutch Guard Do not operate the engine w[...]

19 SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine ma y occur if the intake silencer or filter are removed. Clutches Do not attempt to service the c lutches. All clutch service must be performed by your dealer . The clutch is a complex mechanism that rotates at hi gh [...]

20 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 your machine. Driving in too lit- tle snow will result in excessive wear and damage to the slide rail, track and/[...]

21 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- 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. Ev en seasoned driv- ers should spend som[...]

22 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n 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 empera[...]

23 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[...]

24 SAFETY Safety Decals and Locations T rack/Seat W arning The track/seat warning decal is on the rear of the tunnel: W ARNING Stay clear of track. Do not sit on seat back. Entangle ment with the track or a fall from seat back may result in severe injury or death. Reverse W arnin g Polaris W idetrak snowmobile is equipped with standard reverse. The[...]

25 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[...]

26 FEA TURES AND CONTROLS 1. F uel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may in clude indicator/wa rning lights) 5. Reverse Indicator 6. Mountain Bar 7. Engine Stop Switch (s ee page 54) 8. Throttle Control 9. Choke 10. Recoil Starter Handle 5 4 3 2 1 10 9 7 8 6 General Representation[...]

27 FEA TURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illu strated on this page. Not all models come with these featur es. Refer to your Owner ’ s Manual Supplement. NOTE: Accessories are available from yo ur Polaris dealer . 1. Headlight Dimmer Switch 2. Parkin g Brake Lock 3. Hand[...]

28 FEA TURES AND CONTROLS 1. Hood 2. Headlight 3. Windshield 4. Handleba r 5. Operator Seat 6. P ass enger Ha nd Hold St rap 7. Cargo Rack 8. T aillights 9. Snow Flap 10. T rack 11. Suspension 12. T railing Arm 13. Nosepan 14. F ront Bumper (do not use for pu lling or dragging the snowmobile) 15. Skis Cargo Rack Always secure cargo before operatin [...]

29 FEA TURES AND CONTROLS Backrest The backrest is adjust- able for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment kn obs to move the back- rest forward for operator use or rearward for pas- senger use. 3. Always tighten the knobs Operator/P assenger Raise/Lower[...]

30 THE PERFECT FIT F ront Suspension Adjustments Break in the suspension for approx imately 15 0 miles (240 km) and re- grease all suspension parts before making any fine-tuning 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 se[...]

31 THE PERFECT FIT F ront Suspension Adjustments The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. T o determine if your machine is using full travel of the ski shock, push the jo[...]

32 THE PERFECT FIT F ront Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to- ground pressure. F ront Springs For models without exter- nally adjustable or revalv- able shocks, the front spring s can be changed if spring pre- load alone isn’ t [...]

33 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 condi- tions. However , all suspension designs a nd adjustments involve a c om- promise, or t[...]

34 THE PERFECT FIT WideT rak Rear Suspension Adjustments Rear Spring Settings Rear spring adjustment is primarily a control for riding comfort. T o check for the recommended settings: 1. Lift the rear of the machin e to relieve the rear springs. 2. Slowly lower the machine and m easure the distance between the ground an d the running board . 3. W i[...]

35 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handle bar angle at the hand lebar block. 1. Remove th e mountain bar by removing nut s. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster block (turn the handl ebar eit her left or right for access to the rear nuts). NOTE: If nece[...]

36 THE PERFECT FIT T raction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to a ssist in turning the snowmob ile and to prevent ski wear caused by contact with roads and other bare terrain. Inspect skags frequently . W orn skags may reduce stee ring and braking control on hard-packe d snow and ice. Replac[...]

37 THE PERFECT FIT Accessories Polaris of fers a wide range of acce ssories for your snowmobil e. From map light to electric start, Polaris has the accessories that will he lp make each ride more enjoyable . See your dealer for a list of accessories. Use only Polaris parts and accessories on your Polari s snowmobile. Use of unapproved parts and acc[...]

38 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 Belt Condition 83, 86 Steering Syste[...]

39 PRE-RIDE INSPECTIONS Before St arting 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 Own er ’ s Manual completely and refer to it of[...]

40 PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic Brakes Properly functioning brakes are critical to your safety . Always check the following items to assure proper op eration before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 in ch (1.3 cm). A s maller distance i[...]

41 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 on ly 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 Bra[...]

42 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis complet ely to the right and to the left. If any dif- ficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Ma ke sure all greasable components are properly lubricated. n T rack Use of traction products such as[...]

43 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[...]

44 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 Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating. n Mirr ors (if equipp[...]

45 OPERA TION Starting the Engine NOTICE: Engaging the st arter when the en gine is running WILL result in serious engine dam age, especially if the transmission is in reverse. Never e ngage the st arter when the engine is running. 1. T urn the fuel valve on . See page 2 7. 2. T urn the ke y to the ON position . 3. Pull the engine stop switch up to[...]

46 OPERA TION Engine Break-In No single action on yo ur 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 gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure pr[...]

47 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 50. NOTICE: Serious engin e damage can occur withou t the proper lubrication. Check the oil t ank level of ten during the first t ank of fuel. If the oil level doesn' t go down, cont act your deal er immediately . Oil Recommendations [...]

48 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 sup- port the rear of the snowmobile at the re ar bumper . The track should be approxi- mately 4 inches (10 cm) of f the ground. 2. S tart the engine and allow it to warm up two to three minutes. 3.[...]

49 OPERA TION Fu e l Y our Po laris engine is designed to run on 87 octane n on-oxygenated or 89 octane oxygenated pump gasoline. There’ s a great deal of variability in the quality of the 87 octane gaso line available, so we encourage the use of premium fuel when possible. Do not use lower than 87 octane fuel. Do not u se fuel contai ning mor e [...]

50 OPERA TION 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-oxy genated fuel, Polari s re commends th e regular u se of isopropyl-based fu el system deicer . Add one to two ounces per gallon (8-16 milliliters per li[...]

51 OPERA TION n Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 47 for oil recommendations. When the low oil indicator light is on , oil should be adde d before further operation of the snowmob ile. V isually check the oil level in the bottle. The engine may be operated as long as oil is visible in th[...]

52 OPERA TION n Oil Low Oil Level Always do a visual check of the oil level when refuelin g. When the oil reaches the low leve l mark, add one U.S. quart of recommended oil to the tank. See page 47 for oil recommendations. The Polaris oil cap on the oil tank may be vented to allow proper oil flow . See your Polaris dealer fo r recommended replaceme[...]

53 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e affect 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 e levation s and high er temperatures, the air is less dense. RMK carburetors are preset to operate at altitudes [...]

54 OPERA TION n Engine Stop Switch Push down on the engine stop switch to stop the engine in an emer gency . This will ground out the ignition and bring the engine to a quick stop. T o restart the engine, the switch must be pulled up to the ON position. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all[...]

55 OPERA TION n Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switch to OFF . 2. V isually inspect the throttle cabl e and carburetor(s) 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[...]

56 OPERA TION Emergenc y Stopping The following chart lists methods for stopping the snowmobile in the event of an e mer gency . Re fer to page 54 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 Flood[...]

57 OPERA TION Emergency Starting Y our machine is equipped with a to ol kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. If the recoil starter system fails, an emer gency start strap is provided in the kit. Reverse Operation Mechanical Reverse Make sure the shift lever [...]

58 OPERA TION To w i n g Do not use the f ront bump er to pull or drag the snowmobi le. The front bumper is not de signed for this type of use and may detach from th e vehicle if force is applied. For your safety , do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch function s. If the sno[...]

59 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-[...]

60 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty , and read the maintenance section of your ow ner'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[...]

61 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 120. The recommended maintenanc e schedul e on your snowmob[...]

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

63 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, r eplace if necessary) C - Clean R - Replace L - Lubricate Item See Pa g e Fr e q u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- I I I I Hose Condition -- I I I I Fluid Leaks -- I[...]

64 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Pa g e Fr e q u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Seas on ELECTRICAL Auxiliary Shut-Off Switch 44 I I I I I Throttle Safety Switch[...]

65 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, r eplace if necessary) C - Clean R - Replace L - Lubricate Item See Pa g e Fr e q u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHAS SIS Rear Suspension Pivot Shafts 67 L L L Camber Alignment -- I I I [...]

66 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[...]

67 MAINTENANCE Lubrication Rear Suspension WideT rak Rear Suspension + + + + +[...]

68 MAINTENANCE Lubrication Jackshaft Bearing The jacksh aft bearing on your mo del may be equipped with a grease fit- ting, but this comp onent is greased for life at the factory . Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the[...]

69 MAINTENANCE Lubrication n Gearcase Oil Level (WideT rak) Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 65. Chang e the gear- case oil after the first 500 miles (800 km), then ever y 1000 mile s (1600 km) or seasonally . T o check the oil level, place the machine on a level surface. The oil lev[...]

70 MAINTENANCE Spark Plugs It’ s very important to use the corre ct spark p lug for your machine. A spark plug with a heat range too hi gh will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. In selecting a spark plug heat ra nge for p roduction, a manufacturer assumes that the e[...]

71 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condit ion should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . NOTE: Incorrect fuel mixture can of ten cause a spark plu g to appear too da[...]

72 MAINTENANCE Intake Filter The intake foam filter and screen lim its snow ingestion into the intake system. When operating in loose po wder snow , check the top of the foam filter and screen pe riodically to remove an y accumulatio n of snow . NOTICE: Operating the snowmob ile with the intake filters removed may cause carburetor icin g. The resul[...]

73 MAINTENANCE Carburetor W ater/Sediment T rap Service Most Polaris snowmobiles contain pa tented carbure tor bowl water/sedi- ment traps located at the bottom of eac h carburetor . The trap, consisting of a hose with a pl ug, should be drain ed about every 1000 miles (1 600 km) and inspected for contamination. Plug Cleaning Procedure 1. T urn the[...]

74 MAINTENANCE Carburetor The numb er stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’ s your deal er ’ s responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with in correct jetting can re sult in[...]

75 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 fu el lines regularly for sign s of deterioration or damage. Always check fuel line condition after periods of s torage. N ormal dete- rioration from weather and fuel compounds may occur . Replace w orn or d[...]

76 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at ap proximately 1000 miles (1600 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. Ch eck for weak or missing retaini ng springs or damper/support grommets. Drive Chain T ension[...]

77 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve bef ore each use of the snowmobile. See page 40. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approxima tely 1/16 inch/1.5 mm). A kit is available for replacing brake pads. See y our dealer . Brake Components 1. Br[...]

78 MAINTENANCE Brakes Brake Fluid NOTICE: Brake fluid will damage decals , paint and some plastics. Always wipe up spills immediately . The brake fluid level can be seen through a plastic sight glass in the brake reservoir . If the fluid is suf fic ient, the sight glass will be black. If the sight glass is any color other than black, add brake flui[...]

79 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 sy[...]

80 MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted 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 engin[...]

81 MAINTENANCE Lights NOTE: Avoid touching a ha logen 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 bulb, clean it with an alcohol- moistened towel. Headlight Bulb Replacement 1. Pinch the ends of the spring (1) together and lift until it releases from the[...]

82 MAINTENANCE Clutch System Periodically inspect the clutch sheaves for damage, wear , or belt resi- due. T o maintain optimum performan ce, clean with no n-oil based clean- ers such as isopropyl alcohol. NOTICE: The bushing s in the w eights and rollers of Polaris clut ches are made of a materia l that may be d amaged if lubricated. Do not lubric[...]

83 MAINTENANCE Clutch System n Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Ot her belt s may match the dimensions, but can drastically change the shif t pattern, resulting in poor perfor- mance. See[...]

84 MAINTENANCE Clutch System Drive Belt Removal 1. S top the engine after operating in a forward motion. 2. T urn the ignition key of f. W a it for 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 o pen the clutch guard. 6. Firmly grasp the belt midway between [...]

85 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slac k. NOTE: T o ensure satisfactory belt life, install belt s so they op erate in the same direction of rot a- tion by positioning the identification numb ers so that you ca n read them. If required, sepa- rate the sheaves as outlin[...]

86 MAINTENANCE Clutch System n Drive Belt Deflectio n Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (1) and appl y downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). Drive Belt Adjustment Belt deflection should be adjusted wi thout[...]

87 MAINTENANCE Clutch System To r q u e S t o p Periodically check torque stop clearance. W ith clutches in proper alignment, the torque stop clearance shou ld be .010-.03 0 inch (.25-.75 mm) from the engine case. Adjust if necessary , and lock the jam nut. To o l K i t A tool kit is included with each machine for emer gency and routine maintenance[...]

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

89 MAINTENANCE Tr a c k 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: If excessive rail slide wear occurs due to po or snow conditions, additiona[...]

90 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. T ension adjustments sh ould be made only after the track is warmed up and limber . 1. T urn the engin e off. 2. Lift the rear of the machine and safely su pport it of f the ground. 3. Place the recommended we[...]

91 MAINTENANCE Tr a c k T rack T ension I f the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 7. T ighten or loose n the track adjusting screws as necess ary to pro- vide equal adjustment on both sides of th e track. 8. Repeat the measure- ment on the other sid e of the track. NOTE: Check mo re fre- quently wh[...]

92 MAINTENANCE Tr a c k n T rack Alignmen t 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 su pport the rear of the machine with the track of f the ground. 2. S tart the engine and apply a small amount of throttle until the track tur[...]

93 MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary . Specific fasteners that should be checked are marked with a + in the illustration. + + + + + +[...]

94 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 1/8-1/4 inch (3-6 mm) greater than at point Y . NOTE: If the s[...]

95 MAINTENANCE Steering System n Ski Skags Check skags weekly to maintain pos itive steering characteristics. Skags must be replaced when worn to half their original diameter . NOTE: Carbid e skags must be re placed if any abnormal wear or chip- ping is found. Skag Replacement 1. Raise an d support the fron t of th e machine so the skis are approxi[...]

96 MAINTENANCE Suspension Maintenance n Rail Slide W ear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point alon g their length. F ailure to do so may result in permanent damage to the[...]

97 MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly . Check the battery fluid level often. The fluid level should be k ept between the upper and lower leve l marks. Add only distilled water . T ap water contains minerals that are harmful to a battery . WA R N I N G Battery electrolyte is poisono us. It contains[...]

98 MAINTENANCE Battery Battery Connections Always keep battery terminals and connections free of corrosion. If cleaning is necessary , re move the corrosion with a stif f wire brush. W ash with a s olution of one tablespo on baking soda and one cup water . Rinse well with tap water and dry of f with clean shop towels. Coat the terminals with dielec[...]

99 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It ca n also hinder vehicle performance. 1. Ensure that the battery is fully char ged. 2. Place the battery in the batte ry ho lder . Attach the hold down strap. 3. Install the battery vent tube. NO[...]

100 MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter): • Remove the battery . • Char ge it to the proper level. • S tore it in a cool dry place. • Check and/ or charge monthly . • Have the battery tested and rechar ged before reinstalling it in the vehicle. If a ba[...]

101 MAINTENANCE Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be sus pended appr oximately 4 inche s (10 cm) of f the ground . Remove the key and cover the machine. NOTE: Polaris has acc essory covers and track stands availab le to fit all m[...]

102 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 comp onents. Cleaning and Preservation Proper storage starts with cleanin g, washing, and waxing the hood, chassis, and plastic parts. W ipe down remaining surfaces with [...]

103 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 drai n the fuel tank, use the fol- lowing procedure: 1. T ransfer unused fu el from the fuel tank to an approved fue l con- tainer using a siphon pump. Do not re-use[...]

104 MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack conn ector blocks with diel ectric grease and re-connect. See page 105 for the part n umbers of Polaris products. Replace worn or frayed electrical wi re and conn ectors. Be sure wiring harness[...]

105 POL ARIS PRODUCTS Part No. Descrip tion Engine Lu bricants 2870791 F ogging 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 (gal.) 2872347[...]

106 SUSPENSION TROUBLESHOOTING Problem Solution (p erform only one change at a time) Rear suspension bot- toms too easily • V erify sag dimension (see pa ge 91). Adjust torsion spring blocks or install optional tors ion springs to achieve correct sag dimensions. Rear suspension rides too stiff • Check for binding suspensi on components and grea[...]

107 TROUBLESHOOTING Belt W ear/Burn T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machi ne down. Check belt deflection. Insufficient warm-up W arm the engine at least five minutes. T ake the drive belt of f the machine in extremely col d weather and warm it up . Break machine l oose fr[...]

108 TROUBLESHOOTING Engine T roubleshooting NOTE: Unless you have experience and training in two- cycle engine repa ir , see your dealer if tech nical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during acceler- ation or load variations Drive clutch binding • Disassemble drive clutch to inspect shift weights for we[...]

109 TROUBLESHOOTING Engine T roubleshooting Problem Probable Cause Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing fail ure/ ch ain- case, jacks haft, or front drive shaft • SEE YOUR DEALER. Drive belt surfa ce flat spots • Inspect and replace if necessary . Drive chain loose or worn, sprocket teeth br[...]

110 TROUBLESHOOTING Engine T roubleshooting Problem Probable Cause Soluti on Engine turns but fails to start Faulty ignition • Remove spark plug(s) and rep lace with new plug(s). If engine still fails to start, check for spark; if no spark SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is ON. Check tank level and fill up with cor[...]

111 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[...]

112 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. Polari s snowmobile o wner reports theft. NOTE: A. In addition to notifying the proper law enforcement of fici[...]

113 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[...]

114 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[...]

115 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[...]

116 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[...]

117 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[...]

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

119 W ARRANTY Snowmobile Engine Emis sions Limited W arranty This limited wa rranty excludes fa ilures not caused b y a defect in material or workmanship. This limited warr anty does not cover damage due to accidents, abuse, or improper handling, maintenance or use. This l imited warra n ty also does not cover any engine that has been structur ally[...]

120 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) 2000 mi.[...]

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

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

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

124 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 37 Air Box Warnin g . . . . . . . . . . . . . . . 23 Air Pollut ion . . . . . . . . . . . . . . . . . . . 5 Apparel . . . . . . . . . . . . . . . . . . . . . . 11 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Backrest . . . . . . . . . . . . . . . . . . . . . . 29 Battery . . .[...]

125 INDEX L Lever, Shift (Mecha nical Reverse) . . 57 Lights . . . . . . . . . . . . . . . . . . . . . 80-81 Headlight A djustment . . . . . . . . 80 Lubrication Choke and Cabl e . . . . . . . . . . . . 68 Drives haft Bearing . . . . . . . . . . 68 Jackshaft Bearing . . . . . . . . . . . 68 Rear Suspensi on . . . . . . . . . . . . 67 Throttle Cable[...]

126 INDEX T Throttle Lever . . . . . . . . . . . . . . 39, 55 Throttle Safety Switch . . . . . . . . 39, 54 Tool Kit . . . . . . . . . . . . . . . . . . . . . . 87 Torque Stop . . . . . . . . . . . . . . . . . . . 87 Towing . . . . . . . . . . . . . . . . . . . . . . . 58 Track Alignment . . . . . . . . . . . . . . . . 92 Damage . . . . . . . . . .[...]