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Polaris 2007 Dragon, Owner'S Manual

The Polaris 2007 Dragon Owner's Manual is a comprehensive manual specifically designed for snowmobile enthusiasts. This free downloadable manual provides detailed instructions on how to operate and maintain the Polaris 2007 Dragon, ensuring a smooth and enjoyable riding experience. Download your free copy from manualshive.com.

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77

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You 

may need to increase frequency based on riding conditions. When 

inspection reveals the need for replacement parts, always use genuine 

Polaris parts, available from your Polaris dealer.

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean

R - Replace

L - Lubricate

Item

See 

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset 

(without belt)

96

I

I

I

Drive Belt Condition

97

I

I

I

I

Clutches

96

C

C

C

Belt Tension

--

I

I

I

I

Clutch Sheaves

96

I

I

I

I

ENGINE/COOLING

Engine Mounts

--

I

I

I

I

Recoil Rope

--

I

I

I

I

Engine Torque Stop

101

I

I

I

I

Cylinder Head Bolts

--

I

I

I

Cylinder Base Nuts

--

I

I

I

I

Ignition Timing BTDC

--

I

I

I

VES System

--

C

C

C

I

Coolant Level

87

I

I

R

I

Water Pump Drive Belt

--

I

I

R

Coolant Hose

--

I

I

I

I

Heat Exchangers

89

I

I

I

I

I

Coolant Circulation

--

I

I

I

Coolant Leaks

--

I

I

I

I

Spark Plug Condition

85

I

I

I

R

I

Exhaust Pipe

90

I

I

Exhaust Retaining 

Springs

90

I

I

I

I

Summary of Contents for 2007 Dragon

Page 1: ......

Page 2: ......

Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...evelopment of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Mas...

Page 5: ...ign and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in par...

Page 6: ... of your snowmobile s controls and features The Perfect Fit 39 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 54 This section explains procedures that must be performed before riding Operation 61 This section explains proper engine break in operation of features and general operating procedures Maintenance 74 This section...

Page 7: ...___________________________________ Key Number on key ____________________________________________________ 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 the snowmobile is sold Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components...

Page 8: ...form to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your...

Page 9: ...rt symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note ...

Page 10: ...mobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may bec...

Page 11: ...h feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause s...

Page 12: ...2 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet fac...

Page 13: ... you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone For added pro...

Page 14: ...re necessary for stopping Excessive Speed Always observe all laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per sec ond your machine travels If your speed is 40 MPH your machine is traveling about 60 feet per second If you look back for only two sec onds your machine wi...

Page 15: ...rown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of water When teaching inexperien...

Page 16: ...slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information For more information about avalanche training a...

Page 17: ...ppery Surfaces WARNING Ice and snow build up may interfere with the steering of your machine result ing in serious injury or death Keep the underhood area free of snow and ice WARNING Never attempt an abrupt change of direction when operating on slippery sur faces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss o...

Page 18: ... to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may r...

Page 19: ... you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine ...

Page 20: ...ex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throt...

Page 21: ... down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow WARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious injury CAUTION When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication an...

Page 22: ...tor s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile Jumping may injure your back because of spinal compression The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use Be cou...

Page 23: ...6 93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min Wind Speed in KPH Actual Thermometer Reading _C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature _C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 7 11 14 18 22 ...

Page 24: ... replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service c...

Page 25: ...assenger warning decal is located on the left side of the console or below the steering post Snowmobiles designed for a single rider only have the NO PASSENGER warning decal WARNING This vehicle is designed for operator only NO PASSENGER Snowmobiles designed for an operator and one passenger have the ONE PASSENGER warning decal WARNING This vehicle is designed for operator and ONE passenger only F...

Page 26: ...ehind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward Operation Warning The operation warning decal is...

Page 27: ...nd adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are ...

Page 28: ...1 2 3 4 10 8 12 13 14 1 9 7 6 1 Hood 2 Headlight 3 Windshield 4 Handlebar 5 Operator Seat 6 Taillights 7 Rear Bumper 8 Snow Flap 9 Console Storage Compartment 10 Suspension 11 Track 12 Skis 13 Nosepan 14 Front Bumper ...

Page 29: ...uge 6 Engine Stop Switch 7 Throttle Control 8 Hood Hold Down Straps 9 Recoil Starter Handle 10 Parking Brake 11 Handlebar Grip Warmer Switch 12 Thumbwarmer Switch 13 Electronic Reverse Button 14 Multi Function Display MFD Control 15 Headlight Dimmer Switch 1 2 3 6 7 8 9 14 13 15 10 11 12 4 5 ...

Page 30: ...ases DET activation is temporary and the timing will return to normal automatically In extreme conditions the DET sys tem retards timing and holds it in a retarded state If this occurs replace the fuel with recommended fuel or see your Polaris dealer for service Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or...

Page 31: ...dicator 8 High Beam Indicator Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level i...

Page 32: ...Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer read ings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change preferences press and hold the MODE button for thre...

Page 33: ...r engine RPM whichever setting is selected regardless of the display pro gram being viewed Performance Program The Performance Program automatically displays either speed or tachometer whichever is opposite the analog display See page 29 It also displays electrical system voltage and fuel level if equipped While in the Performance mode press the SET button to cycle through the odometer Trip 1 Trip...

Page 34: ... F automati cally displays when the fuel level is low The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1 4 tank The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1 4 tank The Trip F odometer will automatically ...

Page 35: ...shing press the SET switch once to advance one hour or press and hold the SET button to advance the hour once every 0 2 seconds 3 Press the MODE button to save the hour and flash the minutes 4 Set the minutes in the same manner 5 When finished press the MODE button to save the new setting NOTE If the MODE button is not pressed within ten seconds the clock will automatically save the new entry ...

Page 36: ...re will display as additional screens in the engine program Press the SET button to dis play the ambient air temperature and altitude screens Air Temperature if equipped The MFD displays actual air temperature Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement Hour Meter The hour meter records the total hours of engine operation since manufact...

Page 37: ... 50 feet 15 m or press and hold the button to advance 100 ft 30 m every 0 1 seconds Adjust the altitude display to within 50 ft 15 m of current altitude NOTE The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the cal ...

Page 38: ... the History Program is not currently displayed The History Program will display the history of the Maximum Speed Maximum RPM and Service Interval settings Maximum Speed RPM Reset While in either the MAX MPH or the MAX RPM mode press and hold the SET button for three seconds to reset the recorded maxi mum values for both MPH and RPM Both of these values are reset at the same time Reset the MAX MPH...

Page 39: ...rval 1 Enter the service interval screen 2 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 3 When the display stops flashing release the button The service interval has been reset To reset the reminder at a new interval 1 Enter the service interval screen 2 Press and hold the SET button for five seconds until the hours begin to flash 3 Immedi...

Page 40: ...artment 4 Carefully cut the bottom of the com partment opposite the wires to separate the heat sealed seams Squeeze the corners of the compartment inward so the battery is visible NOTE Note the orientation of the battery before removing it An incor rectly installed battery will not maintain the clock 5 Using needle nose pliers grasp the battery and rotate it slightly so the leading edge of the bat...

Page 41: ...revious cable tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side o...

Page 42: ...nd starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Opti...

Page 43: ...d rotate it Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of preload beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are holding the spring between the retainer on the top of the shock and the threaded ...

Page 44: ...r ride Turn the knob counterclockwise B for a softer ride Shock Valving The shocks can be revalved if spring preload or compression adjust ments aren t sufficient and further adjustment is desired to control sus pension stiffness Please see your Polaris dealer WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform th...

Page 45: ... pension designs and adjustments involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snowcross course See your Polaris dealer for initial suspension setup information Addi tional adjustments can be made after initial setup Make adjustments to one area ...

Page 46: ...n ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Greas...

Page 47: ... hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion ...

Page 48: ... 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 effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm ...

Page 49: ...stment knob on the shock reservoir to make adjustments to the compression damping Positions are labeled on the shock When adjusting we recommend that you turn the adjuster slightly then test ride Turn the knob clockwise A for a stiffer ride Turn the knob counterclockwise B for a softer ride A B ...

Page 50: ...spension coupling Front To Rear Coupling Using the front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque a...

Page 51: ...orque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following ...

Page 52: ...for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position NOTE Your dealer can help you with initial setup and addi tional setup instructions to help you achieve your optimum ride A scissor stop tool is also available fro...

Page 53: ...move the handlebar cover 1 2 Loosen the four upper adjuster block bolts 2 3 Adjust the handlebar to the desired angle 4 Torque the front bolts first then torque the rear bolts Torque the bolts to 11 13 ft lbs 15 18 Nm 5 Reinstall the handlebar cover Handlebar Position Adjust handlebar position as outlined below Refer to the illustration above 1 Remove the handlebar cover 1 2 Loosen the four upper ...

Page 54: ...wmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for ser vice ...

Page 55: ...creased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer CAUTION Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 53 Never add shims to the wear strip Track damage will result because of lack of clearance between upper carrier wheels and track Use of ...

Page 56: ...roper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Wear strips are designed for a specific stud length See your deal...

Page 57: ...teering System 58 Recoil Rope 59 Coolant Level 87 Parking Brake Lock Brake Lever Brake System 56 57 91 Auxiliary Shut Off Switch Engine Stop Switch 60 Ignition Switch 60 Taillight Brakelight Headlight 60 Suspension Mounting Bolts 110 Skags Wear Bars 109 Ski Saddle and Spindle Bolts 110 Hood Straps Latches 59 Seat Latches if equipped 59 Throttle Lever Safety Switch 68 69 Rear Wheel Idler Bolts 105 ...

Page 58: ...ever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately n Throttle Safety Switch Test the throttle safety switch system before the machine is operated S...

Page 59: ...ates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 93 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 92 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always ...

Page 60: ...ely into place Do not force the lock or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly ...

Page 61: ...ur machine result ing in serious injury or death Keep the underhood area free of snow and ice WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track dam...

Page 62: ...ways ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile n Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat latches are securely in place before every use of the snowmobile n Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside...

Page 63: ... n Tether Switch if equipped If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately n Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirrors if equipped Adjust the mirrors so they can be used to their full advantage n Operating Area Before driving away check your surroundi...

Page 64: ...ttempts slightly depress the throttle no more than 1 4I open while cranking the engine When the engine starts immediately release the throttle WARNING Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without checking all components to be sure of proper operation See Before Starting the Engine beginning on page 55 WARNING ...

Page 65: ...hree hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle open ings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engi...

Page 66: ...ine See page 114 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other CAUTION Serious engine damage can occur without t...

Page 67: ...kes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle durin...

Page 68: ...efuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it...

Page 69: ...ces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 114 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be...

Page 70: ...he filler neck Never operate the engine if oil is not visible in the tank NOTE The Polaris oil cap on the oil tank is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated...

Page 71: ...peration 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the eve...

Page 72: ...eplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch mus...

Page 73: ...y See page 68 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit ...

Page 74: ...he strap counter clockwise around the clutch as shown 5 Pull the strap abruptly so the strap comes free of the clutch while starting the engine Repeat until the engine starts 6 Reinstall the side panel 7 Close and secure the hood WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure DO NOT wrap the start strap around your hand...

Page 75: ...E If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the machine is in forward WARNING Improper ...

Page 76: ...with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a tobog gan or sled make sure the pole is at least ...

Page 77: ...l should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 The emission control system designation per SAE J1930 is IFI If yo...

Page 78: ...the manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake system and exhaust valves to be critical emission related maintenance The speci fied maintenance for the fuel filter is recommended...

Page 79: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to...

Page 80: ...00 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 96 I I I Drive Belt Condition 97 I I I I Clutches 96 C C C Belt Tension I I I I Clutch Sheaves 96 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Engine Torque Stop 101 I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I I Ignition Timing BTDC I I I VES System C C C I Coolant...

Page 81: ...Brake System 56 91 I Brake Fluid 92 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 69 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 81 L L L Throttle Position Sensor I I I Fuel Lines 86 I I I I I Fuel Filter 86 R R Oil Filter 83 R R Oil Lines 83 I I I Air Box I I I I I Fuel Injectors I I I ELECTRICAL Auxiliary Shut Off Switch 60 I I I I I Throttle Safety Switch 68 I I I I I Ignition S...

Page 82: ...rs I I I I I Suspension Shock Oil I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearing 81 L L L I Skags Wear Bars 109 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 90 I I I I I Hood Latches 59 I I I I I Rear Wheel Idler Bolts 105 I I I I I Idler Bolt Jam Nut 105 I I I I I Rear Suspension Pivot Shafts 80 L L L Camber Alignment I I I Handlebar Centering I Tether Switch and ...

Page 83: ...on pivot shafts with Polaris Premium All Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For more infor mation about suspension lubrication and adjustments see your Polaris dealer ...

Page 84: ...or housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown ...

Page 85: ...e sight glass 2 Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 114 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level sur face 2 View the oil level at the sight glass 3 Remove the fill plug 3 and add the recommended oil as needed Do not ov...

Page 86: ...e of burrs nicks or scratches 5 Reinstall the drain plug Torque to 6 10 ft lbs 8 13 Nm 6 Remove the fill plug Clean off all metal shavings from the plug 7 Add 11 oz 325 ml of the recommended oil Do not overfill 8 Reinstall the fill plug making sure it is seated properly Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter Have your dealer change the oil filter and bleed the sys...

Page 87: ...plugs every 2000 2500 miles 3200 4000 km CAUTION Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement Use recommended spark plugs with th...

Page 88: ...s over heating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil Spark Plug Removal 1 Remove the spark...

Page 89: ...s dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 77 Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds may oc...

Page 90: ... 60 antifreeze 40 water mixture See page 114 for Polaris products NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system n Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle or overflow tank Engine filler neck Pressure cap Connecting ho...

Page 91: ...ler for service Add coolant if the level is low NOTE Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine ...

Page 92: ...d coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant bottle level Fill as required 7 Feel the heat exchangers under the running boards If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the ...

Page 93: ...before each long trip To obtain correct chain tension 1 Rotate the driven clutch counter clockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the ...

Page 94: ...place when thickness is less than 1 16I 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the machine to an autho rized Polaris dealer for inspec tion and adjustment WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag o...

Page 95: ...ke fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for...

Page 96: ...r valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 7 After bleeding is complete refill the reservoir to the proper level See page 9...

Page 97: ...lean it with an alcohol moistened towel Headlight Bulb Removal 1 Remove the plenum covering from the headlight assembly 2 Lift the rubber boot to expose the bulb 3 Push down on the spring 1 to release it from the housing 4 With the wire harness 2 attached to the bulb 3 withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness 1 2 3 ...

Page 98: ... 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Verify headlight aim Taillight Brakelight Replacement 1 Remove the screws securing the taillight lens 2 Remove the bulb and install a new bulb 3 Reinstall the lens Screws ...

Page 99: ...upplement for recommended center distance for your machine If adjustment is necessary see your dealer WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the machine until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized mod...

Page 100: ...e condition and tension of the drive belt Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist A worn belt will continue to function but will not deliver maxi mum performance Always carry a spare drive belt for emergency use Store the spare belt in the belt and tool storage area which is located on t...

Page 101: ...ded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counterclockwise an additional 1 4 turn by hand and try again 8 Grasp the belt at the lower edge and remove it CAUTION Do not attempt to remove the drive belt after operating in reverse The snow mobile must be stopp...

Page 102: ...operate in the same direction of rotation by positioning the identifica tion numbers so that you can read them If required separate the sheaves as outlined in the belt removal proce dures 2 Rotate the L wrench counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the L wrench 4 Reinstall the side panel 5 Close and secure the hood ...

Page 103: ... be 1 1 4I 3 2 cm Drive Belt Adjustment TEAM Clutch 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 98 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16I jam nut 3 Using a 1 8I Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the...

Page 104: ...Periodically check torque stop clearance With clutches in proper align ment measure rear torque stop clearance from the engine case Clear ance should be 010I 030I 25 75mm Adjust if necessary Lock the jam nut 010I 030I 25 75 mm Rear Torque Stop ...

Page 105: ...st safely lift and support the rear of the snow mobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod damage is found WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate ...

Page 106: ...tional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury...

Page 107: ...downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning TRAC...

Page 108: ...de equal adjust ment on both sides of the track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the machine is new 9 Start the machine and slowly rotate the track at least five revolu tions Let the track come to a stop do not apply brakes 10 Check track alignment see page 106 and adjust as necessary 11 Tighten the locknuts 12 Tighten the idler shaft bolts 13...

Page 109: ...ns Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknu...

Page 110: ...107 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 111: ...between the skis at point X should be 1 8I to 1 4I 3 6 mm greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer cor rect the alignment since camber adjustment may also be affected WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber a...

Page 112: ...6I 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the rear end of the skag 4 Remove the front end of the skag 5 Reverse the steps to install a skag WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or mor...

Page 113: ...time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip n Check suspension mounting bolts for tightness n Check rear idler wheel bolts for tightness See page 105 n Check rear idler adjusting bolt locknuts for tightness n Check front torque arm limiter strap condition n Check rail slide condit...

Page 114: ...remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sun light and covered with a fabric snowmobile cover Plastic tarp may cause con...

Page 115: ...tection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel ta...

Page 116: ...t parts Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss Track and Suspension Moderate track tension should be main tained during summer storage The machine should be supported off the ground to allow the...

Page 117: ...43 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Anitfreeze 60 40 Prem...

Page 118: ... drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melt...

Page 119: ...ow RPM per formance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel ...

Page 120: ...be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Incorrect clutching SEE YOUR DEALER Engine continually backfires Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line i...

Page 121: ...rts from side to side Check ski alignment see page 108 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 44 Check rail slide replace if worn see page 110 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Set static sag see page 44 Check f...

Page 122: ...oid riding in high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for fouled plugs and water ice or dirt in the fuel tank or fuel line Loading machines onto trailers Skis may ...

Page 123: ...on tained in this manual Your dealer is also familiar with Polaris policies and pro cedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowing information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pr...

Page 124: ...e owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notify...

Page 125: ... not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during tr...

Page 126: ...st present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polari...

Page 127: ...overage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 128: ...Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure o...

Page 129: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 130: ...e covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust gas recirculation system components and aftertreatment system components Replacing or repairing other components not covered by this warranty is the responsibility ...

Page 131: ...ses beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified rep...

Page 132: ...er each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 133: ...130 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 134: ...131 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 135: ...20 D DET 27 Detonation Elimination Technology 27 Digital Display 28 Disabled Operators 10 Drive Belt 17 97 D Drive Belt Adjustment 100 Drive Belt Deflection 100 Drive Belt Installation 99 Drive Belt Removal 98 Drive Chain Tension 90 Driver Awareness 12 Driveshaft Bearing 81 Driving Downhill 15 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 14 Driving Responsibly 19 E Electrical Connectio...

Page 136: ...nspection 110 Pressure Cap Warning 21 R Rail Slide Wear 110 Rear Rear Scissor Stop 48 Rear Suspension Adjustments 42 44 Rear Suspension Adjustments IQ 45 49 Rear To Front Coupling 48 Recoil Rope 59 Recommended Maintenance 7 Registration Warranty 122 Reverse 72 Reverse Warning 23 Rider Capacity 11 Riding Apparel 9 Riding Position 8 RRSS 48 Safety Decals 21 24 Safety Symbols 6 Sag 44 Shock Compressi...

Page 137: ...orque Stop 101 Torsion Spring Preload IQ 45 Towing 73 Track 58 Track Alignment 106 Track Care for Storage 113 Track Inspection 102 Track Lubrication 103 T Track Maintenance 102 106 Track Safety 8 Track Tension 43 104 105 Track Warm Up 64 Track Warning 22 Traction Products 52 53 Transporting the Snowmobile 113 Troubleshooting Drive Belt 119 Troubleshooting Engine 115 117 Troubleshooting IQ Suspensi...

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