Polaris 2009 IQ Turbo Switchback Owner'S Manual Download Page 144

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141

TROUBLESHOOTING

Engine and Drive Train Troubleshooting

Engine Overheating

Harsh Drive Clutch Engagement

Drive Belt Turns Over

Drive System Noise

Probable Cause

Solution

Inadequate snow conditions

Stop and cool the engine. Drive into snow

frequently to prevent overheating. See

page 20.

Low coolant

Stop and cool the engine. Check the cool-

ant level. See page 109. Check for leaks.

Bleed the system if the coolant level is

extremely low.

Restricted air flow to radiator

Stop and cool the engine. Clean snow and

debris from the radiator.

Probable Cause

Solution

Worn drive belt

Replace with the recommended belt.

Excessive belt/sheave clearance

See your dealer.

Probable Cause

Solution

Incorrect belt

Replace with the recommended belt.

Incorrect clutch alignment

See your dealer.

Broken or loose engine mount

See your dealer.

Probable Cause

Solution

Broken drive clutch components

See your dealer.

Bearing failure (chaincase, jackshaft or

front drive shaft)

See your dealer.

Flat spots on drive belt surface

Inspect and replace as needed.

Loose drive chain

Inspect and adjust (or replace).

Worn drive chain/broken sprocket teeth

See your dealer.

Summary of Contents for 2009 IQ Turbo Switchback

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Page 3: ...ns 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 th...

Page 4: ...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 abou...

Page 5: ...ts in the design 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...

Page 6: ...of your snowmobile s controls and features The Perfect Fit 50 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 64 This sectio...

Page 7: ...4...

Page 8: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary t...

Page 9: ...f our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that...

Page 10: ...ris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN _________...

Page 11: ...ith their meanings before reading the manual The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that ma...

Page 12: ...snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation w...

Page 13: ...its operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the sno...

Page 14: ...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...

Page 15: ...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 shatterproo...

Page 16: ...longer distances are necessary for stopping Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Cargo Overload Too much weight on the rear of th...

Page 17: ...mobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and tail...

Page 18: ...difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles Look ahead beh...

Page 19: ...now is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow c...

Page 20: ...our speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING Ice and snow...

Page 21: ...event 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 snowmobile pull the rear of the snowmobile around and point th...

Page 22: ...peeds 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...

Page 23: ...nowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and...

Page 24: ...as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of sp...

Page 25: ...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...

Page 26: ...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 W...

Page 27: ...ehicle is designed for operator and ONE passenger only Hot Surface Warning The hot surface warning is located near the rear of the tunnel on applicable models WARNING HOT SURFACE DO NOT TOUCH Burn may...

Page 28: ...avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If...

Page 29: ...wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments When operating with a passe...

Page 30: ...ragging the snowmobile 2 Hood 3 Headlight 4 Windshield 5 Handlebar 6 Fuel Filler Cap 7 Operator Seat 8 Taillights 9 Storage Compartment or Cargo Bag 10 Rear Bumper 11 Snow Flap 12 Track 13 Suspension...

Page 31: ...ever 5 MFD Multi Function Display 6 Engine Stop Switch 7 Throttle Control 8 Hood Hold Down Straps 9 Parking Brake 10 Handlebar Grip Warmer Switch 11 Thumbwarmer Switch 12 Electronic Reverse Button 13...

Page 32: ...t exceed the rack weight limit Do not allow a passenger to sit on the seat back or the cargo rack Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to t...

Page 33: ...adjustability Removing this lockout and using RIDER SELECT posi tion 6 or 7 will result in the handlebars and brake lever contacting other com ponents and interfering with steering and braking This co...

Page 34: ...ail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for m...

Page 35: ...o not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mecha nism is lubricated for life at the factory WARNING Some aft...

Page 36: ...se of a flashing MIL or high temperature indicator serious engine damage may occur with continued operation See your Polaris dealer 1 Verify that all electrical connections are secure 2 Check battery...

Page 37: ...selected speed sensor error Reverse 5300 Engine will mis fire at higher engine speed Defective rollover switch speed sensor error Rollover 6000 Throttle stuck throttle lever depressed speed sensor err...

Page 38: ...stutter If you do not notice the flashing indicator on the MFD or do not suffi ciently cool the snowmobile the engine will misfire to alert you to look at the MFD and take action Again driving the sn...

Page 39: ...the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the s...

Page 40: ...h 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 cranksha...

Page 41: ...g or with the engine off If the engine is off make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge The gauge will illuminate for abou...

Page 42: ...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 viewing preferences press and hold the MODE button for three...

Page 43: ...See page 39 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following...

Page 44: ...ped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip F odometer records distance traveled...

Page 45: ...seconds 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour T...

Page 46: ...he following screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost Hour Meter The hour meter records the total hours of e...

Page 47: ...vance quickly by 100 foot 30 m incre ments 5 Adjust the altitude display to within 50 ft 15 m of current altitude Tip The gauge reads barometric pressure and allows the rider to compensate for daily f...

Page 48: ...Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until...

Page 49: ...dometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the re...

Page 50: ...active 3 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour incr...

Page 51: ...y compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable...

Page 52: ...ake sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable...

Page 53: ...tory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow cond...

Page 54: ...ceed one inch of pre load 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 hold ing the spring between t...

Page 55: ...er adjusts preload See your Polaris dealer for more information Switchback only The front springs can be changed if spring preload alone isn t sufficient and further adjustment is desired to control s...

Page 56: ...ay vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep...

Page 57: ...ce 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 measure ment X This is meas...

Page 58: ...a firmer ride is desired See your dealer for more information Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a ride...

Page 59: ...urn the adjustment 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 te...

Page 60: ...ar suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the...

Page 61: ...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...

Page 62: ...est 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 accelera...

Page 63: ...ts on the bottom of the adjuster block turn han dlebar to left or right for access to back nuts Tip If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be...

Page 64: ...nowmobile 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...

Page 65: ...ack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tu...

Page 66: ...tain 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 Wea...

Page 67: ...ock Brake Lever Brake System 67 68 115 Throttle Lever 65 Throttle Safety Switch 65 Auxiliary Shut Off Switch Engine Stop Switch 71 85 Ignition Switch 71 85 Taillight Brakelight Headlight 71 Coolant Le...

Page 68: ...e throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion...

Page 69: ...lace before operating the snowmo bile n Steering System Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If dif...

Page 70: ...lic system Refer to the brake bleeding infor mation on page 117 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 11...

Page 71: ...place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service...

Page 72: ...s and cause other track damage Examples of marginal lubri cation would include frozen bodies of water without snow cover icy trails and no snow conditions Track damage or failure caused by operation o...

Page 73: ...he follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 127 Rear idler adjusting bolt locknuts Tightness Torq...

Page 74: ...ure the engine stops when the ignition switch is turned to OFF n Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirror Adjustment...

Page 75: ...vel before operating a snowmobile that has tipped over or rolled over In the event of a tip over or rollover the engine will stop To restart the engine turn the key to the OFF position then restart WA...

Page 76: ...s 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 Nev...

Page 77: ...l throttle or high speeds for extended periods during the break in period Use of non recommended oil may cause serious engine damage Always use the recommended oil for your Polaris snowmobile 1 Fill t...

Page 78: ...attempt to start the engine without using the throt tle If two to three attempts are unsuccessful apply 1 8 to 1 4 throttle while cranking the engine Ease off the throttle immediately when the engine...

Page 79: ...mobile battery Never attempt to jump start a discharged battery that is frozen WARNING Improperly connecting or disconnecting jumper cables can result in an explo sion and cause serious injury or deat...

Page 80: ...able to the fuel system or fuel lines 8 Pull back the red plastic boot covering the positive terminal of the weak battery Connect one end of the positive jumper cable to the positive terminal of the w...

Page 81: ...ure that they have a good electrical connections Repeat step 14 16 If the engine still does not start remove the jumper cables as out lined in step 17 and transport the snowmobile to an authorized Pol...

Page 82: ...t Always protect painted surfaces when handling fuel Fuel Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one...

Page 83: ...d it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure the rear sup port is stable WARNING Use of traction products such as studs ice g...

Page 84: ...ff the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions Tip It will take longer to warm up the t...

Page 85: ...use vehi cle speed and engine speed to be limited This four stroke snowmobile has a self diagnostic check of the throttle safety switch The switch operation is checked through the engine con trol unit...

Page 86: ...ine doesn t start take the snowmobile to an authorized Polaris dealer for service Tip Excessive freeplay in the throttle cable may cause the safety switch to acti vate preventing the engine from start...

Page 87: ...verse button on the left hand control for one second then release Tip A reverse light on the instrument panel will indicate that the snowmobile is in reverse 4 Apply the throttle slowly to make sure t...

Page 88: ...off 3 Apply the throttle slowly to make sure the snowmobile is in for ward n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 82...

Page 89: ...ove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can res...

Page 90: ...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 If...

Page 91: ...s 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...

Page 92: ...er feel O Coolant 109 Inspect level add as needed O Brake fluid 116 O CHANGE EVERY 2 YEARS Hood Latches 66 Secure properly replace if damaged O Seat Latches 65 O Rail Slide 128 Inspect for wear or dam...

Page 93: ...erify alignment adjust as needed O O O Drive Chain 114 Verify tension adjust as needed EVERY Gearcase Oil 102 Check at 500 mi 800 km change every 1000 mi 1600 km O EVERY 1000 1600 Rear Suspension 101...

Page 94: ...es Inspect for wear damage and proper routing replace as needed O O Brake Pads Disc 115 Inspect replace if worn or damaged O O Fuel Vent Lines 106 Inspect replace if worn or damaged O O Ski Toe 130 Ve...

Page 95: ...s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil bran...

Page 96: ...erature is within the specified range for performing the oil check Allow the engine to cool if necessary When the coolant is within the specified range restart the engine and allow it to idle for no m...

Page 97: ...bottom of the safe operating range on the dipstick 9 If the level is high remove 2 ounces 60 ml and recheck the level NOTICE Do not overfill the oil tank Engine damage may occur Always add oil in sma...

Page 98: ...evel check procedure begin ning on page 92 4 If oil is not present add 1 2 quart 47 l of the recommended oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and rech...

Page 99: ...turn over the engine without starting it You may also need an assistant to help with the oil change 1 Position the vehicle on a level surface 2 Make sure the engine coolant temperature is between 145...

Page 100: ...rom the fuse block 11 Reinstall the left side panel 12 Have an assistant use the ignition key to turn over the engine Crank the engine for 15 seconds 13 Wait 30 seconds to allow the starter motor to c...

Page 101: ...einstall the 20A EFI Fuse 21 Remove the dipstick from the oil tank Add 2 quarts 1 9 liters of the recommended oil Reinstall the dipstick 22 Start the engine and allow it to idle for 3 5 minutes Make s...

Page 102: ...ure to avoid overfilling If the filling and checking procedure is not completed within three minutes rein stall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circ...

Page 103: ...or replace the element as recommended The foam oil breather element is located inside the airbox 1 Open the hood 2 Release the airbox cover retain ing clips and remove the cover 3 Remove the foam bre...

Page 104: ...ricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Seaso...

Page 105: ...umbers of Polaris products The dipstick is located on the lower front side of the gearcase Maintain the oil level in the safe operating range between the upper and lower marks on the dipstick 1 Positi...

Page 106: ...breather element See page 100 1 Position the vehicle on a level sur face 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely Tip The sealing surfaces on the d...

Page 107: ...he engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Use only resistor...

Page 108: ...engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Spark Plu...

Page 109: ...laris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on pag...

Page 110: ...s or more as shown tighten the belt or install a new belt Air Filter Inspect the air filter for oil and dirt accumulation at the intervals out lined in the Periodic Maintenance Table beginning on page...

Page 111: ...r cracks or damage Check for weak or missing retaining springs or damper support grommets 4 Replace any damaged or missing components 5 Clean the plastic surfaces next to the muffler with aerosol Carb...

Page 112: ...tem Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part n Coolant Level The engine...

Page 113: ...rature indicator light is illuminated can result in serious engine damage Always stop the snowmobile and cool the engine when the high temperature indicator light illuminates Drive in adequate snow to...

Page 114: ...service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 89 In addition bleed the cooling sys tem any time one or mor...

Page 115: ...rvoir bottle should be full but may have a small air bubble in the top CAUTION Never start the engine when the pressure cap is removed 6 Reinstall the pressure cap Start the engine and allow it to idl...

Page 116: ...cap and add coolant through the filler neck until the reservoir bottle is full Reinstall the pressure cap and start the engine 12 Repeat steps 10 11 until the the coolant level in the bottle no longe...

Page 117: ...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 3 Finger tighten the adjuster bolt until it can no longe...

Page 118: ...is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection an...

Page 119: ...ht glass is any color other than black add brake fluid WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic me...

Page 120: ...alve 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 t...

Page 121: ...b withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into...

Page 122: ...EFI RELAY EX SENSOR GAUGE 20A REVERSE SHIFT Exhaust sensor Gauge Reverse shift Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power EFI 20A Cam phase sensor ECU hold on po...

Page 123: ...timum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine...

Page 124: ...om temperature Reinstall it before starting the snowmobile n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the be...

Page 125: ...on Tip For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a...

Page 126: ...operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the...

Page 127: ...ommended for your model Track Inspection 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track...

Page 128: ...track warranty NOTICE High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequen...

Page 129: ...pecified distance see chart ahead of the center of the rear idler wheel Tip Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the check...

Page 130: ...to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate...

Page 131: ...re evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting...

Page 132: ...129 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners...

Page 133: ...he skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may a...

Page 134: ...nowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the...

Page 135: ...inder vehicle per formance Follow the battery charging instructions on page 134 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Conne...

Page 136: ...ed during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the...

Page 137: ...n before and 1 2 hours after the end of charg ing WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes ve...

Page 138: ...paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile compon...

Page 139: ...ured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained dur ing summer storage The snowmobile should be supporte...

Page 140: ...etic 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 car...

Page 141: ...ay be iced up or fro zen to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Probable Cause Solution Low battery voltage Recharge the battery...

Page 142: ...Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Probable Cause Solution Weak spar...

Page 143: ...rk plug Inspect clean and or replace spark plug Kinked or plugged fuel vent line Inspect and replace Clogged air filter Inspect and clean or replace Air flow through intake is too warm Boost is limite...

Page 144: ...tor Stop and cool the engine Clean snow and debris from the radiator Probable Cause Solution Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Probable...

Page 145: ...climb ing Set static sag see page 54 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 55 Machine darts from side to side Check ski...

Page 146: ...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 perfor mance Check for fouled plugs or...

Page 147: ...contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the followi...

Page 148: ...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 number and the mode...

Page 149: ...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 ha...

Page 150: ...t 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 deale...

Page 151: ...verage 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 he...

Page 152: ...overage 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 requi...

Page 153: ...ake 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 verific...

Page 154: ...t are covered by this warranty This includes all com ponents whose failure increases the snowmobile engine s emissions Replacing or repairing other components not covered by this warranty is the respo...

Page 155: ...entified 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 stro...

Page 156: ...r 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...

Page 157: ...154 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 158: ...155 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 159: ...ystem 109 113 Cooling System Bleeding 111 113 Cooling System Flushing 111 D Digital Display 37 Disabled Operators 13 Drive Belt 19 Drive Belt Adjustment 121 Drive Belt Condition 121 Drive Belt Deflect...

Page 160: ...19 MFD Battery Replacement 48 49 MFD Components 37 MFD Digital Display Programs 40 47 MFD Settings 38 39 N Noise 6 O Oil Engine 92 99 Gearcase 102 103 Oil Breather Element 100 Oil Breather Filter 107...

Page 161: ...ips 53 Suspension Front 50 Switches Stop Switch 82 Throttle Safety Switch 82 T Throttle Cable Lubrication 101 Throttle Lever 65 83 Throttle Safety Switch 65 82 Tip Over Inspections 72 Torsion Spring P...

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