Polaris 440 IQ Owner'S Manual Download Page 66

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MAINTENANCE

Lubrication

Lack of lubrication will adversely affect your ride and the life of

components. Lubricate 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. A grease gun kit, complete with

grease and adaptors, is available to lubricate all fittings on Polaris

snowmobiles. See page 99 for the part numbers of Polaris products.
For more information about suspension lubrication and adjustments,

see your Polaris dealer.

NOTE:

Lubrication points are indicated by a

in the following

illustrations.

Rear Suspension

Summary of Contents for 440 IQ

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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 The engine exhaust from this product contains chemicals known to the State...

Page 4: ...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...

Page 5: ...gn and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publicatio...

Page 6: ...controls and features The Perfect Fit 28 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 42 This section explains procedure...

Page 7: ...ns Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific milea...

Page 8: ...at snowmobiles conform 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 o...

Page 9: ...cle Identification Numbers Record your snowmobile s identification numbers in the spaces provided Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number right front side o...

Page 10: ...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 sa...

Page 11: ...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 12: ...with the engine running Stop the engine raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur...

Page 13: ...er a signaling mirror a means of building a fire and a two way radio or cellular telephone For added protection carry the following items on your snowmobile at all times SSpare Drive Belt SExtra Set o...

Page 14: ...or in inclement weather Always observe all state and local laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will e...

Page 15: ...ur view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on con...

Page 16: ...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 conditions above you as you travel in mou...

Page 17: ...ard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving Downhil...

Page 18: ...balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If...

Page 19: ...lex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive...

Page 20: ...ive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the thr...

Page 21: ...ills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can ben...

Page 22: ...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 CHILL CHART...

Page 23: ...s read and follow the instructions of the decals on the snowmobile If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provi...

Page 24: ...ls and Locations Track Warning The track warning decal is located on the rear of the tunnel Passenger Warning This snowmobile is designed for one operator only A No Passenger warning decal is located...

Page 25: ...22 SAFETY Safety Decals and Locations Operation Warning...

Page 26: ...23 SAFETY Safety Decals and Locations Operation Warning...

Page 27: ...Stop Switch 5 Throttle Control 6 Choke Control 7 Recoil Starter Handle 8 Fuel Filler Cap 9 Park Brake Lock 10 Headlight Dimmer Switch 11 Handlebar Grip Warmer Thumbwarmer Switch 12 Tether Switch 13 Ma...

Page 28: ...25 FEATURES AND CONTROLS 1 Handlebar 2 Windshield 3 Headlight 4 Hood 5 Nosepan 6 Skis 7 Track 8 Suspension 9 Snow Flap 10 Taillights 11 Seat 9 4 11 10 7 8 5 6 1 2 3...

Page 29: ...AGON mode for normal trail riding S Unnecessary extended or excessive use of DRAGON mode can re sult in severe engine damage which is excluded from Polaris war ranty coverage S DRAGON mode usually hea...

Page 30: ...See page 52 2 When staged at the starting line depress and hold the DRAGON horn button on the left handlebar 1 3 Slowly advance the throttle to the wide open position while keeping the button depresse...

Page 31: ...hen 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 r...

Page 32: ...set as low as possible to use the full travel of the ski shock with occasional light bottoming To determine if your machine is using full travel of the ski shock push the o ring travel indicator down...

Page 33: ...d Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the upper sprin...

Page 34: ...anical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recom...

Page 35: ...change For further assistance see your dealer Suspension Performance Tips S Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding s...

Page 36: ...er ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desire...

Page 37: ...There are two types of rear suspension coupling 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 amou...

Page 38: ...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...

Page 39: ...ase weight transfer or ski lift during acceleration move the RRSS to the rearward upper position The RRSS may also be rotated to a lower position for even more weight transfer if desired A Low Positio...

Page 40: ...two bolts on the top of the riser depending on the type of adjustment required 3 Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do...

Page 41: ...sories on your Polaris snowmobile Use of unapproved parts and accessories may result in S Non compliance with government industry requirements S Voiding of warranty S Personal injury to self or others...

Page 42: ...ed by contact with roads and other bare terrain The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control Similarly if your machine is equip...

Page 43: ...rack damage will result because of lack 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 cent...

Page 44: ...dding is used Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components as viewed from the rear of the track 1 Top of tunnel...

Page 45: ...ms Item See Page Item See Page Drive Belt Condition 84 85 Steering System 46 Recoil Rope 46 Coolant Level 73 Park Brake Lock Brake Lever Brake System 45 77 Auxiliary Shut Off Switch Engine Stop Switch...

Page 46: ...g n Check Throttle and Brake for Proper Operation The throttle and brake are the primary controls of your snowmobile If either should malfunction loss of control could result Make sure the throttle le...

Page 47: ...in the hydraulic system Refer to the brake bleeding information on page 80 Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See pa...

Page 48: ...o not force the lock or it may break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake l...

Page 49: ...me in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy...

Page 50: ...ing Check the headlight high and low beam taillight and brake light for normal operation n Check Surroundings to Verify Clear Operating Area Make sure you have a clear area all around your snowmobile...

Page 51: ...ge 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 openings and machine speeds to reduce friction on...

Page 52: ...l Serious chemical reactions can cause system blockage resulting in serious engine damage They may also be incompatible and the result could be sludge formation filter blockage and reduced cold weathe...

Page 53: ...ng is performed or where gasoline is stored S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an e...

Page 54: ...ll extended position or allow it to snap back into the housing Damage may result To avoid personal injury and or engine damage do not operate the recoil pull rope starter while the engine is running 5...

Page 55: ...hine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle during warm up or when the track is free hanging Be sure the rear sup...

Page 56: ...ciently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side...

Page 57: ...ne performance A lean mixture may be caused by things like fuel line restrictions foreign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Page 58: ...or altitude range The main jet installed in production is not correct for all altitudes and or temperatures CAUTION A main jet that s too small will cause a lean operating condition and may cause seri...

Page 59: ...AT IT DOES THROTTLE CONDITION Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Tether Switch Interrupts ignition circuit All WARNI...

Page 60: ...tarting procedure DO NOT wrap the start strap around your hand Keep all bystanders and loose clothing away from the snowmobile when using the emergency starting procedure To use the emergency start st...

Page 61: ...to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object...

Page 62: ...tervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty peri...

Page 63: ...Drive Belt Condition 84 I I I I Clutches disassemble 83 C C C Belt Tension I I I I Clutch Sheaves 83 I I I I Engine Engine Mounts I I I I Recoil Rope I I I I Engine Mounting Plate I I I Engine Torque...

Page 64: ...I I I I Brake System 43 77 I Brake fluid 79 R Fuel Management Pilot Air Screws I I I Carburetor synchronize 54 I I I Idle RPM I I I Throttle Lever 43 I I I I I Throttle Cable 65 L L L Choke Cable 65...

Page 65: ...I Ski Spindle 64 L L L L I Steering Post U Joint 64 L L L L L Steering Arm s 63 L L L L I Upper Lower Steering Post Support Bracket 63 L L L L I Drive Chain Tension 76 I I I I I Hood Straps 46 I I I...

Page 66: ...00 km after that and before off season storage each year A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles See page 99 for the part numbe...

Page 67: ...on Two components of the IQ front suspension and steering require lubrication S Grease the left and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle ar...

Page 68: ...f turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubricate the choke slide 2 and cables lightly with oil or grease Before turning the engine off operate the choke int...

Page 69: ...k A Add Polaris synthetic chaincase oil through the dipstick opening Do not overfill See page 99 for the part numbers of Polaris products Flush the chaincase after the first 500 miles then every 1000...

Page 70: ...ment for the specific spark plug to be used in your machine CAUTION A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than int...

Page 71: ...own There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white...

Page 72: ...e powder snow check the top of the foam filters periodically to remove any accumulation of snow CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing The result w...

Page 73: ...9 The use of other lubricants may cause improper function of the valve mechanism and increase the frequency of required cleaning due to excessive build up of carbon deposits Fuel Filter Fuel Lines Ins...

Page 74: ...e damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or bala...

Page 75: ...Check for weak or missing retaining springs or damper support grommets WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this pr...

Page 76: ...Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models If the engine coolant reaches a certain temperature the switch comp...

Page 77: ...er for the correct part Use of a non standard pressure cap will not allow the recovery system to function properly Bleeding the Cooling System CAUTION If coolant flow becomes restricted or plugged coo...

Page 78: ...the coolant bottle is the highest point in the cooling system Cycle the RPM as outlined in step 3 NOTE There must be enough coolant flow to purge the air from the front close off cooler so you can obs...

Page 79: ...nsioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be adjusted by...

Page 80: ...be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 1 6 mm A kit is available for replacing brake pads See your dealer WARNING Brake failure during operat...

Page 81: ...Brake Pad Material Replace when thickness is less than 1 16 Excessive Brake Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 77 the m...

Page 82: ...ity of accident or severe injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the...

Page 83: ...r reservoir cover and gasket 2 Fill the master cylinder reservoir to between the MIN and MAX marks Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the...

Page 84: ...the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be...

Page 85: ...Lift spring carefully around wire harness 2 and flip to outside of housing 3 With the wire harness attached to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate...

Page 86: ...ect the clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol Clutch Alignment and Offset Clutch center distance an...

Page 87: ...kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough to remove the belt Drive Belt Installation 1 Drop the drive belt o...

Page 88: ...ster 2 Using a 1 8 Allen wrench adjust the threaded set screw C as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the dis...

Page 89: ...led it s especially important to maintain track tension as specified on page 88 WARNING Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle control an...

Page 90: ...r His experienced and trained service technician will keep your machine in peak operating condition Tool Kit A tool kit is included with each machine for emergency and routine maintenance Always keep...

Page 91: ...fely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see Track Tension Data below ahead of the center of the rear idler wheel NOTE...

Page 92: ...ill cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turn...

Page 93: ...nd Track Lubrication WARNING Operating with insufficient lubrication between the slider and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can resu...

Page 94: ...91 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all fasteners and tighten if necessary Specifically check fasteners marked with a...

Page 95: ...Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The...

Page 96: ...s to maintain proper vehicle control while turning on hard packed snow or ice Check skags weekly to maintain positive steering characteristics Skags must be replaced when worn to half their original d...

Page 97: ...d cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the following items on a weekly basis or before any long trip n Ch...

Page 98: ...n with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause conde...

Page 99: ...resh premixed fuel Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following procedure 1 Transfer unused...

Page 100: ...connect See page 99 for the part numbers of Polaris products Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage mo...

Page 101: ...alve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel supply on 2 NOTE The fuel valve is located under the hood 2 Be sure the fuel cap is installe...

Page 102: ...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 P...

Page 103: ...clearance and replace if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over...

Page 104: ...elt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t turn Seized engine Hydrostatic lock SEE YOUR DEA...

Page 105: ...may be necessary to change plug s however the plug s may operate satisfac torily when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEAL...

Page 106: ...ack tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check slider and re...

Page 107: ...educe RPM Avoid riding in high ambient temperatures 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 a...

Page 108: ...3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris C...

Page 109: ...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...

Page 110: ...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 deal...

Page 111: ...cuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered con...

Page 112: ...tomatic with no additional 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 validat...

Page 113: ...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 114: ...111 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km...

Page 115: ...112 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 116: ...113 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 117: ...hain Tension 76 Driver Awareness 12 Driving Downhill 14 Driving in Hilly Terrain 15 Driving on Slippery Surfaces 14 Driving Responsibly 18 E Electrical Connections 97 Emergency Starting 57 Emergency S...

Page 118: ...s 67 68 Start the Engine and Check 47 Starting Emergency 57 Starting a Cold Engine 51 Starting a Warm Engine 51 Starting the Engine 51 Steering Adjustment 91 S Steering Inspection 91 Steering System 4...

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Polaris 440 IQ, Owner'S Manual

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Summary of Contents for 440 IQ

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